CN113477941A - 一种增材制造铝合金零件自润滑涂层电沉积工艺 - Google Patents
一种增材制造铝合金零件自润滑涂层电沉积工艺 Download PDFInfo
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Abstract
本发明公开了一种增材制造铝合金零件自润滑涂层电沉积工艺,设计样件模型、选区激光熔化增材制造、切割零件并进行手工打磨,然后对零件进行化学镀Zn‑Ni预处理、喷射电沉积纯Ni涂层中间处理、分散二硫化钼,最后喷射电沉积自润滑层,得到的自润滑涂层与铝合金表面结合紧密,涂层中二硫化钼的含量在合适范围内,从而使得铝合金表面具有较低的摩擦系数和较高的使用寿命。
Description
技术领域
本发明涉及一种表层电沉积工艺,尤其是一种增材制造铝合金零件自润滑涂层电沉积工艺。
背景技术
目前在铝合金基底上制备自润滑涂层的技术有化学复合镀技术、复合氧化技术、电沉积复合镀技术等,鉴于通过已有技术,可以采用对铝合金零件进行表面电沉积自润滑涂层,以此来提高表面区域的耐磨性,提高零件的使用寿命。
选区激光熔化技术利用高功率的激光束将金属粉末逐层熔化沉积成形,基体经热辐射作用后沉积层温度迅速升高,金属粉末快速熔化,激光束离开后迅速凝固,由于激光能量稳定性较低、成形时间过短,其成形件内部易发生球化、裂纹、孔隙等各种缺陷影响制件的质量。除此之外,由于激光热辐射过程中存在温度梯度较大,熔池凝固后材料内部有残余应力生成,极易引发、翘曲、微裂纹等缺陷。球化会导致零件表面质量较差,而裂纹是选区激光熔化技术中影响制件质量和力学性能的重要缺陷,飞溅会导致金属粉末脱离基体材料,使得沉积层的粉末量不足,发生孔隙、球化等缺陷,并且飞溅回落在基体后,经过下一层金属粉末的覆盖,夹杂在成形件内部影响制件质量。由于球化、飞溅现象的出现,金属粉末脱离基体造成沉积层粉末量不足,冷却凝固后形成孔隙;熔池冷却过程中产生氧化物、碳化物等各类夹杂物易剥离表面形成孔洞;粉末使用前未烘干会导致粉体间粘度过大且无法致密排列,使得铺粉时粘连运动辊带离铺粉层,成形时由于粉末量不足造成孔隙;在熔化过程中,由于高纯Ar保护气进入到高温熔池内部,当光斑作用区域移开熔道后熔池迅速冷却,高纯Ar保护气难以溢出,导致气孔缺陷的发生。球化、裂纹、孔隙、翘曲、微裂纹等缺陷会对选区激光熔化增材制造铝合金零件的耐摩擦磨损性能产生很大影响,影响零件的使用寿命。
喷射电沉积作为局部电化学沉积的一种,大大改善了电解液的流动性,具有电流密度大、电流效率高、定域性强、工艺简单、成本低等优点,在喷射电沉积加工过程中,电解液以高速射流的形式喷向阴极进行电沉积,这种强烈紊流形式的流动,加快了溶液的搅拌速度,降低了扩散层的厚度,增强了电化学极化,极大地提高了极限电流密度,可以以远高于其它电沉积工艺的电流密度进行,金属沉积速度大大提高,实现更高效率的局部电沉积。配合选区激光熔化增材制造铝合金基体材料的前处理技术,可以快速制备自润滑涂层,以提高其耐摩擦磨损性能及使用寿命。
发明内容
为解决增材制造铝合金零件耐磨性差的问题,本发明提供一种增材制造铝合金零件自润滑涂层电沉积工艺,使用喷射电沉积工艺在增材制造铝合金表面加工,得到自润滑涂层。
本发明的目的通过以下技术方案实现:
本发明提供了一种增材制造铝合金零件自润滑涂层电沉积工艺,包括以下步骤:
步骤一,设计样件模型,通过切片软件得到用于选区激光熔化增材制造的打印文件;
步骤二,以铝基金属粉末为原料,通过选区激光熔化机床进行铝合金零件的增材制造;
步骤三,基板切割零件,将步骤二得到的增材制造零件运用电火花线切割将零件从基板切下;
步骤四,打磨,将步骤三得到的零件进行打磨;
步骤五,化学镀Zn-Ni预处理,将步骤四得到的零件在无水乙醇中超声清洗之后,进行化学镀Zn-Ni预处理;
步骤六,喷射电沉积纯Ni中间处理,将步骤五得到的零件喷射电沉积纯Ni涂层中间处理;
步骤七:分散二硫化钼,将一定量的二硫化钼放置在一定量的去离子水中进行超声分散;
步骤八:喷射电沉积自润滑涂层,将步骤七得到的二硫化钼分散溶液倒入电沉积液中,进行喷射电沉积自润滑涂层。
优选的,步骤一所述的样件模型下方设有柱状支撑结构,便于样件从基板上切割下来。
优选的,步骤二中所述铝基金属粉末为AlSi10Mg粉末,粒径为20-53μm。
优选的,所述增材制造为选区激光熔化增材制造,增材制造参数激光功率为350W,扫描速度为1500mm/s,扫描间距为60μm,基板预热温度为80℃,层厚为40μm,成型舱体内使用氩气保护,并维持舱体压力为0.5-1.0MPa。
优选的,步骤四中所述打磨采用手工打磨,步骤为依次使用200#、400#、800#、1000#、1500#、2000#砂纸进行手工打磨,提高零件表面的平面度。
优选的,所述步骤五所述化学镀Zn-Ni预处理,是将步骤四处理的工件在100-120g/L的氢氧化钠、8-10g/L的氧化锌、15-18g/L的氯化镍、1-2g/L的硫酸铁和10-12g/L的酒石酸钾钠配制的溶液中进行化学镀Zn-Ni处理,工艺条件为:温度28-30℃,时间25-30s,处理完后立即取出,用大量去离子水清洗工件表面残留的溶液,并用去离子水浸泡25-30min后取出。
优选的,步骤六所述喷射电沉积纯Ni涂层中间处理,是将经步骤五得到的零件在电沉积液中喷射电沉积一层纯Ni涂层,所述电沉积液包括镍盐、缓冲剂、光亮剂和表面活性剂;其中镍盐控制在260-300g/L,缓冲剂控制在35-40g/L,光亮剂控制在3-5g/L,表面活性剂控制在0.05-0.06g/L,电沉积的电流密度100A/dm2,时间为10min,温度控制在40℃±1,pH控制在4.0±0.1,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。
优选的,所述步骤七中的二硫化钼平均粒径为800nm,二硫化钼使用质量为3g,去离子水使用量为100ml,超声分散的时间为30min-60min。
优选的,所述步骤八中喷射电沉积自润滑涂层,是将步骤七分散的二硫化钼溶液倒入步骤六所述的电沉积液中,电流密度为25A/dm2,时间为50min,温度控制在40℃±1,PH控制在4.0±0.1,磁力搅拌转速2000r/min,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。
有益效果:
(1)本发明采用的超声分散二硫化钼可以使得纳米二硫化钼得到很好的分散,不会造成团聚;
(2)本发明通过喷射电沉积可以使二硫化钼高效的嵌入涂层中,有利于发挥出二硫化钼的润滑效果;
(3)通过本发明得到的选区激光熔化增材制造铝合金零件,润滑涂层与铝合金表面结合紧密,涂层中二硫化钼的含量在合适范围内,从而使得铝合金表面具有较低的摩擦系数和较高的使用寿命。
附图说明
图1为本发明一个实施例的工艺流程图;
图2为本发明一个实施例的零件三维模型图;
图3为本发明一个实施例的增材制造零件实物图片;
图4为本发明一个实施例的自润滑涂层的微观表面形貌;
图5为本发明一个实施例的纯Ni涂层与自润滑涂层的摩擦系数随时间的变化曲线图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明公开了一种在进行相对摩擦运动的增材制造铝合金零件表面自润滑涂层的处理工艺,并希望其可以在自润滑状态下能够提升耐磨性和使用寿命。如图1所示,为本发明的工艺流程图。
步骤一,设计样件模型,通过切片软件得到用于选区激光熔化增材制造的打印文件。如图2所示,通过三维建模软件SolidWorks绘制所需加工样件的三维模型,并保存为STL格式文件,再通过Magics软件对样件添加柱状支撑,并保存为STL文件,再通过AutoFab软件对STL文件进行切片和参数设置,得到用于选区激光熔化机床识别的最终文件。样件模型下方设有柱状支撑结构,便于样件从基板上切割下来。
步骤二,以铝基金属粉末为原料,通过选区激光熔化机床进行铝合金零件的增材制造使用选区激光熔化机床制备的样件,铝基金属粉末为AlSi10Mg粉末,粒径为20-53μm。选区激光熔化增材制造使用的激光功率为350W,扫描速度为1500mm/s,扫描间距为60μm,基板预热温度为80℃,层厚为40μm,成型舱体内使用氩气保护,并维持舱体压力为0.5-1.0MPa。
步骤三,基板切割零件,将步骤二得到的增材制造样品使用电火花线切割机床将零件从基板切下。
步骤四,打磨,将步骤三得到的零件进行手工打磨。将得到的增材依次使用200#、400#、800#、1000#、1500#、2000#砂纸进行手工打磨。
步骤五,将打磨后的零件在无水乙醇中超声清洗5min之后,进行化学镀Zn-Ni预处理。化学镀Zn-Ni预处理是将超声清洗后的工件在100-120g/L的氢氧化钠、8-10g/L的氧化锌、15-18g/L的氯化镍、1-2g/L的硫酸铁、10-12g/L的酒石酸钾钠配制的溶液中进行化学镀Zn-Ni处理,工艺条件为:温度28-30℃,时间25-30s,处理完后立即取出,用大量去离子水清洗工件表面残留的溶液,并用去离子水浸泡25-30min后取出。
步骤六,喷射电沉积纯Ni中间处理,将步骤五得到的零件喷射电沉积纯Ni涂层中间处理。将经过化学镀Zn-Ni预处理得到的零件喷射电沉积纯Ni涂层中间处理。喷射电沉积纯Ni涂层中间处理是将经过化学镀Zn-Ni预处理后得到的零件在包括镍盐、缓冲剂、光亮剂、表面活性剂等组成的电沉积液中喷射电沉积一层纯Ni涂层,其中镍盐控制在260-300g/L,缓冲剂控制在35-40g/L,光亮剂控制在3-5g/L,表面活性剂控制在0.05-0.06g/L,电流密度为100A/dm2,时间为10min,温度控制在40℃±1,pH控制在4.0±0.1,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。
步骤七:分散二硫化钼,取3g/L平均粒径为800nm二硫化钼放置在100ml的去离子水中进行30-60min超声分散。具体为:将超声分散的二硫化钼溶液倒入电沉积液中,进行喷射电沉积自润滑涂层。喷射电沉积工艺参数:电流密度为25A/dm2,时间为50min,温度40℃±1,pH4.0±0.1,磁力搅拌转速2000r/min,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。得到增材制造零件实物如图3所示。
利用扫描电子显微镜(SEM)和高速往复摩擦磨损试验机对所得的样品进行表征。如图4所示,为该涂层在扫描电镜下的微观形貌。使用球-盘接触方式进行摩擦磨损试验。试验所用对磨球为之间3mm的302不锈钢球。其他试验参数:正压力2N,旋转速度150r/min,旋转半径3mm,摩擦时间10分钟。
如图5所示,为纯Ni涂层与自润滑涂层的摩擦系数随时间的变化曲线。纯Ni涂层的摩擦系数约为0.51,自润滑涂层的摩擦系数约为0.18。可以看出,经过本发明的处理之后,润滑涂层与铝合金表面结合紧密,使增材制造铝合金表面具有具有较低的摩擦系数和较长的自润滑寿命。
最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (9)
1.一种增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:包括以下步骤:
步骤一,设计样件模型,通过切片软件得到用于选区激光熔化增材制造的打印文件;
步骤二,以铝基金属粉末为原料,通过选区激光熔化机床进行铝合金零件的增材制造;
步骤三,基板切割零件,将步骤二得到的增材制造零件运用电火花线切割将零件从基板切下;
步骤四,打磨,将步骤三得到的零件进行打磨;
步骤五,化学镀Zn-Ni预处理,将步骤四得到的零件在无水乙醇中超声清洗之后,进行化学镀Zn-Ni预处理;
步骤六,喷射电沉积纯Ni中间处理,将步骤五得到的零件喷射电沉积纯Ni涂层中间处理;
步骤七:分散二硫化钼,将一定量的二硫化钼放置在一定量的去离子水中进行超声分散;
步骤八:喷射电沉积自润滑涂层,将步骤七得到的二硫化钼分散溶液倒入电沉积液中,进行喷射电沉积自润滑涂层。
2.根据权利要求1所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤一所述的样件模型下方设有柱状支撑结构,便于样件从基板上切割下来。
3.根据权利要求2所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤二中所述铝基金属粉末为AlSi10Mg粉末,粒径为20-53μm。
4.根据权利要求3所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤二中所述增材制造为选区激光熔化增材制造,使用的激光功率为350W,扫描速度为1500mm/s,扫描间距为60μm,基板预热温度为80℃,层厚为40μm,成型舱体内使用氩气保护,并维持舱体压力为0.5-1.0MPa。
5.根据权利要求4所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤四中所述打磨采用手工打磨,步骤为依次使用200#、400#、800#、1000#、1500#、2000#砂纸进行手工打磨,提高零件表面的平面度。
6.根据权利要求1或5所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤五所述化学镀Zn-Ni预处理,是将步骤四处理的工件在100-120g/L的氢氧化钠、8-10g/L的氧化锌、15-18g/L的氯化镍、1-2g/L的硫酸铁和10-12g/L的酒石酸钾钠配制的溶液中进行化学镀Zn-Ni处理,工艺条件为:温度28-30℃,时间25-30s,处理完后立即取出,用大量去离子水清洗工件表面残留的溶液,并用去离子水浸泡25-30min后取出。
7.根据权利要求6所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤六所述喷射电沉积纯Ni涂层中间处理,是将经步骤五得到的零件在电沉积液中喷射电沉积一层纯Ni涂层,所述电沉积液包括镍盐、缓冲剂、光亮剂和表面活性剂;其中镍盐控制在260-300g/L,缓冲剂控制在35-40g/L,光亮剂控制在3-5g/L,表面活性剂控制在0.05-0.06g/L,电沉积的电流密度100A/dm2,时间为10min,温度控制在40℃±1,pH控制在4.0±0.1,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。
8.根据权利要求7所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤七中所述二硫化钼平均粒径为800nm,二硫化钼使用质量为3g,去离子水使用量为100ml,超声分散的时间为30min-60min。
9.根据权利要求8所述的增材制造铝合金零件自润滑涂层电沉积工艺,其特征在于:步骤八中所述喷射电沉积自润滑涂层,是将步骤七分散的二硫化钼溶液倒入步骤六所述的电沉积液中,电流密度为25A/dm2,时间为50min,温度控制在40℃±1,PH控制在4.0±0.1,磁力搅拌转速2000r/min,镀完的样件用去离子水进行清洗,并在去离子水中浸泡30min后取出。
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