CN113310762A - 用于测定热喷涂金属或合金涂层比热容样品的制备方法 - Google Patents
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Abstract
本发明涉及一种用于测定热喷涂金属或合金涂层比热容样品的制备方法，属于涂层测试技术领域。首先用金属或合金作为基体，对基体上表面除油并进行喷砂毛化，然后进行热喷涂，直至涂层将表面完全覆盖并形成一定厚度；磨削涂层上表面，然后用线切割分离出涂层部分，再对涂层样品进行切割面的磨削，制成测试样品大样；对制备的测试样品大样进行线切割制取小样，并对小样表面打磨，直至符合比热容样品测试要求。本发明方法制备的样品完全能有效测试各种热喷涂金属或合金涂层的比热容。
Description
技术领域
本发明涉及一种用于测定热喷涂金属或合金涂层比热容样品的制备方法，属于涂层测试技术领域。
背景技术
热喷涂是利用热源将金属或非金属材料加热到熔融或半熔融状态，通过高速气流将其雾化成微小颗粒，喷射到经过处理的工件表面上形成涂层，从而使工件表面获得耐磨、耐腐、耐热、抗氧化、隔热、绝缘、导电、密封、防微波辐射以及其它特殊物理化学性能的一种工艺方法。
热喷涂金属或合金材料可以是粉末、丝材和棒材三种形式，它们主要被用来制备耐磨、耐腐、导电、导热等性能的涂层。由于热喷涂最常用的基体是金属或合金，可以直接在基体上喷上涂层并进行后续加工。热喷涂金属或合金涂层在使用过程中有时由于涂层与基体比热容的差异，造成运行过程中精确控制含涂层的制件一定时间内涂层的热容量及温度难以实现的现象。为更好地使用涂层以达到相应耐磨、耐蚀、导电、导热等目的，有必要测试涂层的比热容。
对于一定块体金属材料诸如钢铁、铝合金、钛合金等的比热容的测定所用样品通常是用磨削或其它加工工艺方法把材料加工成规定的测试用样品后按规定程序进行测试。但由于热喷涂金属或合金涂层适应性宽，应用场合范围大，对涂层的制备往往采用不同的工艺，在这种情况下，即使是同种材料也会由于制备工艺的不同，造成涂层中的结构、组织不同，从而导致其比热容可能有所差异。
以往可以采用粉末冶金法制备成分相同的样品再进行加工，但这样测试的数据只能供对比，与实际涂层的比热容有一定差异。因为用粉末冶金法做涂层的比热容测定样品时影响因素很多，包括粉末颗粒大小、粉末成分均匀性、压制压力、烧结温度、烧结时间、压制后样品的孔隙率、孔隙大小、孔隙分布等等，无法将喷涂工艺的真实性复制到粉末冶金件。另外，由于喷涂时根据具体功用和成本的不同，对涂层的制备往往采用不同的工艺，在这种情况下，即使是同种材料也会由于制备工艺的不同，造成涂层中的结构、组织不同，从而可能导致不同的比热容。对特定条件下制备的涂层比热容的测定能较好地反映涂层提高(降低)温度所需热量(减少热量)的能力。因此，热喷涂金属或合金涂层比热容的测定对于反映涂层材料吸热或放热的能力，精确控制一定时间内涂层的比热容物理性能显得尤为重要。
发明内容
本发明的目的在于提供一种用于测定热喷涂金属或合金涂层比热容样品的制备方法。本发明主要是采用金属或合金基体，对金属或合金基体进行相应的清洗、毛化处理，再采用相应的热喷涂工艺在金属或合金基体上喷涂所要测定的热喷涂材料，制样后进行后续磨削加工，制备出符合要求的上表面，再将其按一定厚度进行线切割分离，使其成为厚度均匀的薄片，再将切割面磨削加工，直至测试样所需的规定厚度，最后按要求切割成比热容做需要的圆片试样，并进行最后的表面和侧圆周打磨，然后进行一定温度下的比热容测定。
为实现上述目的，本发明采用以下技术方案：
一种用于测定热喷涂金属或合金涂层比热容样品的制备方法，包括如下步骤：
(1)用金属或合金作为基体，对基体上表面除油并进行喷砂毛化，然后进行热喷涂，直至涂层将表面完全覆盖并形成一定厚度；
(2)磨削涂层上表面，然后用线切割分离出涂层部分，再对涂层样品进行切割面的磨削，制成测试样品大样；对制备的测试样品大样进行线切割制取小样，并对小样表面打磨，直至符合比热容样品测试要求。
本发明的方法中，在热喷涂前，对金属或合金基体用除油剂进行除油，并在常压下进行表面喷砂毛化。
样品采用热喷涂工艺制备，所述的热喷涂包括等离子喷涂、超音速火焰喷涂(HVOF)、电弧喷涂、火焰丝材喷涂、爆炸喷涂和冷喷涂等。
所述的热喷涂采用的材料可以是铁、镍、钴、铝和锌等金属，或铁基合金、镍基合金、钴基合金、铝基合金和锌基合金等合金，材料的形态可以是金属或合金丝材、金属或合金粉末、金属复合粉末、金属或合金棒材。
在采用热喷涂制备涂层时，采用断续喷涂，保证基体表面温升低于180℃。
不管采用何种热喷涂工艺和何种热喷涂材料，制备样品时，其基体均为金属或合金等能导电的材料，基体的形状可为圆柱体或长方体。
所述的热喷涂形成的涂层厚度≥1.2mm，优选为1.2-1.5mm。
本发明制备的用于测定热喷涂金属或合金涂层比热容样品的形状为薄圆片或长方体。
本发明的优点：
对本发明方法制备的涂层样品进行比热容的测定能较好地反映涂层在一定温度下的热容量特性，一定程度上反映涂层材料提高温度所需热量的能力，从而反映涂层的本征物理特性。因此，本发明热喷涂金属或合金涂层比热容的测定对于反映涂层热量的传递能力有一定的意义。
本发明方法制备的样品完全能有效测试各种热喷涂金属或合金涂层的比热容。这种样品完全采用实际喷涂设备、工艺制备，与真正的工件上制备的涂层完全一样，组织呈典型的层片状，其内部的孔隙受喷涂工艺、喷涂设备、喷涂材料等影响，而粉末冶金法则是利用一定形状、大小的粉末颗粒压制成型烧结而成，其颗粒之间会存在一定的间隙，造成孔隙，其孔隙的大小受原始粉末的颗粒形貌、大小、流动性、压力大小、烧结工艺有关，样品并无层状组织结构，也无法反映与喷涂工艺、喷涂设备甚至是喷涂材料(喷涂材料可以是丝材)的相关性，不能反映喷涂特征，显然本发明的方法制备的样品更能反映喷涂层样品特征，测试结果更符合喷涂层特性，也更为准确。
附图说明
图1-1至图1-4为金属或合金基体及喷涂后基体和表面涂层的示意图，其中，图1-1：圆柱体基体，图1-2：圆柱体基体及表面涂层，图1-3：长方体基体，图1-4：长方体基体及表面涂层。
图2-a1至图2-c2为在金属或合金基体上喷涂一定厚度后加工出的用于测试比热容的圆形体或长方体涂层样品示意图，其中，图2-a1、图2-a2：涂层大样，图2-b1、图2-b2：切割小样后的大样，图2-c1、图2-c2：最终测试样。
图3-1和图3-2为本发明制备的比热容样品的照片，其中，图3-1：涂层大样，图3-2：实际测试样。
图4为Inconel 600喷涂层比热容测试结果。
具体实施方式
本发明热喷涂金属或合金涂层比热容测定样品是以金属或合金基体，不管采用何种热喷涂工艺和何种热喷涂材料，制备样品时，其基体均为金属或合金型能导电的材料，基体的形状可为圆柱体或长方体，如图1-1和图1-3所示；在喷涂前需对金属或合金基体(上表面)用合适除油剂除油，并用正常压力进行表面喷砂毛化，之后采用等离子喷涂、超音速火焰喷涂、电弧喷涂、普通火焰粉末(丝材)喷涂、棒材喷涂或冷喷涂等喷涂工艺在金属或合金基体上喷涂涂层，直至涂层将表面完全覆盖并达到制样所需的厚度(≥1.2mm)为止，基体及涂层如图1-2和图1-4所示。为防止过热造成涂层与基体过早分离，无论采用何种喷涂工艺制备样品时，为保证样品的成功制备，喷涂时采用断续喷涂，保证基体表面温升低于180℃。喷涂所用材料可以是金属或合金粉末、复合粉末、金属或合金丝材、金属棒材等。样品喷涂所用材料可以是铁基合金、镍基合金、Co基合金、Al基合金、Zn基合金等金属或合金，材料的形态可以是金属或合金丝材、单金属或合金粉末、金属复合粉末、单金属或合金棒材。
对金属或合金基体涂层覆盖的样品进行取样，具体做法是：喷涂后样品上表面进行磨削，磨削后按一定厚度(测试样厚度+加工余量)进行线切割将含磨削过的涂层样品与基体端连接部分分离，分离后再磨削涂层样品线切割面，直至符合测试所需厚度和表面粗糙度要求，得到大样。最后在磨削过的涂层样品大样上按最终比热容的测试样品尺寸(考虑加工余量)进行测试样切割取小样，对小样切割后所有暴露面进行打磨直至完全符合比热容样品测试要求，即标样要求即可，通常是
的圆片。两个不同阶段的样品如图2-a1至图2-c2所示，图2-a1和图2-a2是涂层大样，图2-b1和图2-b2是切割小样后的大样，图2-c1和图2-c2是最终测试样，本发明制备的用于测定热喷涂金属或合金涂层比热容样品为一定尺寸的薄圆片或薄长方体。
按照本发明方法制备的典型Inconel 600喷涂层比热容测试结果见图4。即使同种材料，不同喷涂工艺或不同喷涂设备制备的涂层样品测得的比热容也会不同，因此，采用与工件上涂层相同的制备方法来制备涂层样品更能准确反映工件上涂层的比热容。
实施例1
本实施例1是等离子喷涂CoCrW涂层的比热容测定用样品的制备。圆柱体形钢基体除油并上表面毛化，用等离子喷涂工艺在毛化后的表面喷涂CoCrW涂层，期间采用断续喷涂工艺，直至CoCrW完全覆盖柱体表面并厚度达到1.4mm。用磨床磨削喷涂表面，磨削后按厚度1.2mm用线切割分离，分离后的涂层样品也进行磨削，直至厚度1.05mm，再进行测试样切割制备，如图3-1所示，并进行最终打磨，制备出
的CoCrW涂层圆片，上下端面平行度偏差小于0.05，如图3-2所示。此时的样品完全可以用于CoCrW涂层比热容的测定。
实施例2
本实施例2是超音速火焰喷涂(HVOF)NiCr-Cr3C2涂层的比热容测定用样品的制备。长方体形的Incone 600合金基体除油清洗后毛化，并用超音速火焰喷涂工艺在毛化后的基体上喷涂NiCr-Cr3C2涂层，期间采用断续喷涂工艺，直至NiCr-Cr3C2涂层厚度达到1.4mm，用磨床磨削喷涂层表面，磨削后按厚度1.2mm用线切割分离，分离后的NiCr-Cr3C2涂层样品也进行磨削，直至厚度1.05mm，再进行测试样切割制备并进行最终打磨，制备出
的NiCr-Cr3C2涂层圆片，上下端面平行度偏差小于0.05。此时的样品完全可以用于NiCr-Cr3C2涂层比热容的测定。
实施例3
本实施例3是电弧喷涂1Cr18Ni9Ti不锈钢涂层的比热容测定用样品的制备。用圆柱体形的Al合金作基体，除油清洗后毛化，并用电弧喷涂工艺在毛化后的基体上电弧喷涂1Cr18Ni9Ti不锈钢涂层，期间采用断续喷涂工艺，直至1Cr18Ni9Ti不锈钢涂层厚度达到1.4mm，用磨床磨削喷涂层表面，磨削后按厚度1.2mm用线切割分离，分离后的1Cr18Ni9Ti不锈钢涂层样品也进行磨削，直至厚度1.05mm，再进行测试样切割制备并进行最终打磨，制备出
的1Cr18Ni9Ti不锈钢涂层圆片，上下端面平行度偏差小于0.05。此时的样品完全可以用于1Cr18Ni9Ti不锈钢涂层比热容的测定。
实施例4
本实施例4是冷喷涂TC4钛合金涂层的比热容测定用样品的制备。用长方体形的黄铜作基体，除油清洗后毛化，用冷喷涂工艺在毛化后的基体上喷涂TC4合金涂层，期间采用断续喷涂工艺，直至TC涂层厚度达到1.4mm，用磨床磨削喷涂层表面，磨削后按厚度1.2mm用线切割分离，分离后的TC4涂层样品也进行磨削，直至厚度1.05mm，再进行测试样切割制备并进行最终打磨，制备出
的TC4涂层圆片，上下端面平行度偏差小于0.05。此时的样品完全可以用于TC4涂层比热容的测定。
Claims (8)
1.一种用于测定热喷涂金属或合金涂层比热容样品的制备方法，包括如下步骤：
(1)用金属或合金作为基体，对基体上表面除油并进行喷砂毛化，然后进行热喷涂，直至涂层将表面完全覆盖并形成一定厚度；
(2)磨削涂层上表面，然后用线切割分离出涂层部分，再对涂层样品进行切割面的磨削，制成测试样品大样；对制备的测试样品大样进行线切割制取小样，并对小样表面打磨，直至符合比热容样品测试要求。
2.根据权利要求1所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：在热喷涂前，对金属或合金基体用除油剂进行除油，并在常压下进行表面喷砂毛化。
3.根据权利要求1所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：所述的热喷涂包括等离子喷涂、超音速火焰喷涂、电弧喷涂、火焰丝材喷涂、爆炸喷涂和冷喷涂。
4.根据权利要求3所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：所述的热喷涂采用的材料为金属铁、镍、钴、铝或锌，或者铁基合金、镍基合金、钴基合金、铝基合金或锌基合金，材料的形态为金属或合金丝材、金属或合金粉末、金属复合粉末、金属或合金棒材。
5.根据权利要求4所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：采用热喷涂制备涂层时，采用断续喷涂，使基体表面温升低于180℃。
6.根据权利要求5所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：所述的热喷涂形成的涂层厚度≥1.2mm。
7.根据权利要求1所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：所述基体的形状为圆柱体或长方体。
8.根据权利要求1所述的用于测定热喷涂金属或合金涂层比热容样品的制备方法，其特征在于：所述用于测定热喷涂金属或合金涂层比热容样品的形状为薄的圆片或长方体。
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