CN114717516B - 一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法 - Google Patents
一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法 Download PDFInfo
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Abstract
本发明公开了一种TiAl/Ti2AlC强结合耐腐蚀涂层。首先,利用高功率脉冲磁控溅射系统,通过溅射纯度为99.95%的TiAl靶(Ti:Al=1:1),在基体表面沉积晶体结构为密排六方结构的TiAl层;然后,同时利用高功率脉冲磁控溅射源和直流磁控溅射源共溅射TiAl靶和石墨靶,在TiAl层表面沉积Ti‑Al‑C层,得到TiAl/Ti‑Al‑C双层涂层;最后,进行热处理,使Ti‑Al‑C层转化为Ti2AlC MAX相涂层(相纯度>83wt.%)。该方法制备过程简单,易于控制,制备的复合涂层具有良好的致密性,具有高的耐海水腐蚀特性。
Description
技术领域
本发明属于表面工程技术领域,具体涉及一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法。
背景技术
目前,随着科技技术的不断发展,材料器件应用的领域也越来越广泛,服役环境也越来越严苛,对耐腐蚀涂层的要求也越来越高,如海洋环境下的耐腐蚀涂层。
针对不断变化的应用环境,耐腐蚀涂层也经历了从单元到多元的发展过程,涂层结构也从单层逐步发展为复合多层。现有研究表明,众多涂层体系中过渡金属氮/碳化物是常用的涂层体系。
专利号CN113046703A的中国专利公开了一种高硬度纳米复合涂层及其制备方法与应用,包括依次形成于基体表面的过渡层和TiAlCN层,所述TiAlCN层的物相结构包括硬质纳米金属相及非晶相,所述非晶相均匀分布于所述硬质纳米金属相中,所述硬质纳米金属相包括Ti(C,N)相、TiN相、TiC相、AlN相中的任意一种或两种以上的组合,所述非晶相包括非晶碳相。但是这类涂层在海洋等严苛环境下的服役时耐蚀性能显得略有不足,难以满足复杂工况下的性能需求。
与传统过渡金属氮/碳化物不同,MAX 相是一种兼具金属和陶瓷特性的具有热力学稳定、具有密排六方结构的层状材料,其中,M 代表前过渡金属,A代表IIIA或IVA主族元素,X代表C或N,层与层之间依靠M原子和A原子之间弱的金属键结合,使其具有良好的导电导热性、自愈合性、抗氧化性能等。Ti2AlC是MAX相中常见的化合物,目前多以电弧、喷涂等技术得到,但喷涂、电弧离子镀等技术制备得到的涂层表面粗糙,且涂层中存在较多杂相,这些缺陷不仅为腐蚀离子提供了快速扩散通道,而且易产生电偶腐蚀,这都会降低涂层在实际应用过程中的氧化/腐蚀寿命。
专利号CN107620033B的中国专利公布一种高纯强致密MAX相涂层的制备方法,包括采用电弧离子镀与磁控溅射技术相结合,其中电弧提供M位元素,磁控提供A位Al元素,通入氮气或碳氢反应气体沉积,之后采用热处理,实现高纯强致密MAX相涂层的制备。该方法制备的MAX相涂层纯度高、致密性好、无微观缺陷。利用该方法制备的MAX相纯度较低,无法满足在海洋恶劣环境下耐腐蚀的要求。
因此,发展以MAX相为主的耐蚀涂层制备工艺,制备表面光滑、结构致密、相纯度较高的Ti2AlC涂层显得尤为重要。
发明内容
本发明公开了一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,该制备方法能够制备高纯度的Ti2AlC MAX相涂层,以及具有较高耐腐蚀相,较强结合力的TiAl/Ti2AlC涂层。
一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,包括:
(1)选用TiAl合金作为靶材,氩气作为反应气体,采用高功率脉冲磁控溅射的方法在基体表面沉积TiAl涂层;
(2)然后打开C靶材,采用高功率脉冲磁控溅射和直流磁控技术共溅射方法在TiAl涂层表面沉积Ti-Al-C层;其中,TiAl合金靶材是采用高功率脉冲磁控溅射方法,C靶采用直流磁控技术溅射
(3)通过退火工艺使Ti-Al-C层发生固相反应转变为Ti2AlC MAX相防护涂层。
在退火热处理过程中,通过TiAl层向Ti-Al-C层提供Al原子,补充热处理过程中Ti-Al-C层中的Al原子向外扩散而造成的损失,进而使得Ti-Al-C层获得足够Al原子形成Ti2AlC MAX相防护涂层,并且TiAl层阻碍了基体的杂质元素向Ti-Al-C层的扩散从而获得了较高纯度的Ti2AlC MAX相,达到获得较高耐腐蚀性的涂层的目的。
所述TiAl层的结构为密排六方结构,与Ti2AlC MAX相的拓扑结构类似,从而使得制备的得到的涂层具有较高的结合力。
所述基体包括TC4或不锈钢。
步骤(1)中,所述TiAl合金靶材的功率为80-120 W,基体偏压为-150-0 V。进一步的,所述TiAl合金靶材的功率为110-120 W,基体偏压为-100--50 V。
TiAl合金靶材功率过低,Al原子受到氩离子的撞击,Al原子提供过少进而影响MAX相的转变,TiAl合金靶材功率过高,使得Al原子间的碰撞增大进而造成了Al原子的缺失,进而影响MAX相的转变。
步骤(2)中,基体偏压为 -150-0 V,所述碳靶功率为20-50 W。
所述碳靶功率过低,则容易在MAX相中存在较多的TiAl杂质相,所述碳靶功率过高,则容易在MAX相表面形成大颗粒,使得表面不光滑,影响MAX相的结晶,且还会生成TiC相杂质,所述TiC相、TiAl相杂质能够与MAX相形成电势差,从而影响涂层的耐腐蚀性。
所述退火工艺为:退火温度为600-900℃,时间为1-5 h。
所述TiAl涂层为密排六方结构,厚度为0.5-1 μm,元素原子比为Ti:Al=1-6:4,所述Ti-Al-C层厚度为3-7 μm,元素原子比大致在6:5:2-4:3:3比例区间。
进一步的,所述TiAl层厚度为 0.5-0.7 μm,所述Ti-Al-C层厚度3-6 μm。
在所述退火温度和时间下,当TiAl的厚度过薄则Al原子过快的扩散至外部,Ti-Al-C层无法获得足够的Al原子,当TiAl的厚度过厚,TiAl层的Al原子无法获得足够的能够扩散至Ti-Al-C层,同样Ti-Al-C层无法获得足够的Al原子。
在沉积TiAl层和Ti-Al-C层过程中,腔体的气压为0.4-2 Pa。进一步的,在沉积TiAl层和Ti-Al-C层过程中,腔体的气压为0.5-1.5 Pa。
本发明采用所述的强结合高耐蚀TiAl/Ti2AlC涂层的制备方法制备强结合高耐蚀TiAl/Ti2AlC涂层,所述TiAl/Ti2AlC涂层中的Ti2AlC MAX相的纯度>83 wt.%。
与现有技术相比,本发明的有益效果为:
1)为了解决涂层表面质量问题,本发明通过高功率脉冲磁控技术和直流磁控技术共溅射制备了一种TiAl/Ti2AlC强结合耐腐蚀涂层,高功率脉冲磁控技术给予靶材原子较大的能量,使其离开靶材表面,在偏压的牵引下,沉积在基体表面,可形成光滑的无明显大颗粒的涂层,从而形成具有良好致密性的涂层,进而提高涂层的耐腐蚀和氧化性能。
2)所述涂层具有TiAl/Ti2AlC双层结构,TiAl层晶体结构为密排六方结构,这与Ti2AlC具有相同的晶体结构,使得TiAl层和Ti2AlC之间有着更好的晶格匹配度,同时,还具有相似的热膨胀系数和力学性能,使得涂层具有较高的膜基结合力,以保证涂层在实际环境中服役时不会过早的剥落失效。
3) TiAl层可作为屏障层,防止基体的中的易扩散元素向基体扩散 ,提高涂层热稳定性;同时,TiAl层其中的Al元素在退火时向表层的Ti-Al-C层扩散,防止表层的Ti-Al-C层中的Al元素在退火时的扩散损失,保证Ti2AlC MAX相涂层的相纯度高达83 wt.%以上。
综上,TiAl/Ti2AlC双层功能协同,使其具备较强的膜基结合力的同时也具有较好的耐腐蚀特性。
附图说明
图1为实施例1制备的TiAl层的XRD图谱;
图2为实施例1制备的Ti-Al-C系MAX相涂层扫描电镜图;
图3为实施例1制备的Ti-Al-C系MAX相涂层的XRD图谱;
图4为实施例2制备的Ti-Al-C系MAX相涂层的XRD图谱;
图5为实施例4制备的Ti-Al-C系MAX相涂层的XRD图谱;
图6为对比例1以Ti2AlC MAX相作为主要相的涂层的扫描电镜图;
图7为对比例1以Ti2AlC MAX相作为主要相的涂层的XRD图谱;
图8为实施例1、对比例1和对比例5(基体)的腐蚀性能测试对比图;
图9为实施例1制备的Ti-Al-C系MAX相涂层的结合力图。
具体实施方式
下面结合实施例详述本申请,但本申请并不局限于这些实施例。
本申请的实施例中分析方法如下:
利用X射线衍射仪(XRD)进行相结构和相含量分析;
利用扫描电镜(SEM)进行涂层腐蚀前后形貌,成分分析。
利用划痕仪进行涂层膜基结合力测试;
下面结合附图和实施例,对本发明的具体实施方式作进一步详细的描述,以下实施例仅用于说明本发明,但不用来限制本发明的范围。
实施例1:在本实施例中,基体作为服役于海水环境器件的TC4件,基体表面的Ti-Al-C系MAX相涂层制备方法如下:
将基体依次用丙酮和酒精清洗,去除表面的油脂和可溶性杂质,放入腔体中,待腔体内的压强达到10-3 Pa时开始给基体加热至400 ℃保温5 min,关闭加热。待真空度达到2.0×10-3 Pa以下,向腔通入50 sccm的氩气,设置基体偏压为-400 V,利用电离的氩离子清洗样品30 min。
将温度加热到300 ℃,并保持,采用高功率脉冲磁控溅射沉积TiAl过渡层,其中阴极靶提供Ti和Al源,溅射靶功率调节为115 W。氩气流量设置为20 sccm,腔体压强设置为0.60 Pa,基体偏压为-100 V,沉积时间为30 min,沉积得到的TiAl过渡层为 0.5 μm。
分别采用高功率脉冲磁控溅射电源和直流电源在过渡层表面沉积Ti-Al-C层,TiAl靶功率保持不变,碳靶功率调节为37 W,氩气流量为20 sccm。控制气压为0.6 Pa,基体偏压为-100V,沉积温度为300 ℃,沉积时间为6 h,得到TiAl/Ti-Al-C。
将镀膜样品放在管式炉中,真空度达到2.0×10-3 Pa以下,对样品进行退火处理,升温速度为10 ℃/min,退火温度为700 ℃,保温2 h。
图1实施例1制备的TiAl层的XRD图谱
图2为制得的Ti-Al-C系统的涂层的扫描电镜图,可以看出退火后得到的光滑致密的MAX相涂层以及化学成分能谱图,说明涂层成功被制备到基体表面。
图3为制得的Ti-Al-C系统的MAX相涂层的XRD图谱,说明涂层的相为Ti2AlC,涂层的相纯度达到96 wt.%。
将样品封装制样,放入到配置好的海水溶液中,图8的动电位腐蚀极化图显示相较于对比例1和2,本发明制备得到的涂层样品的腐蚀电流密度为2×10-11 A/cm2,相较于对比例1的2×10-9 A/cm2和对比例1的8×10-8 A/cm2的腐蚀电流密度,本发明的耐蚀性明显高于前两者。
图9为实施例1制备的Ti-Al-C系MAX相涂层的结合力图,数据显示在81.3 N的位置涂层剥落,该涂层膜基结合力强。
实施例2:与实施例1不同的是,本对比例中偏压采用了-80 V,经700 ℃退火处理后,样品的相纯度达到了83 wt%,仅有少量的TiAl存在,对其进行电化学测试得到其腐蚀电流密度为2×10-10 A/cm2,结合力达到70 N,其中,图4实施例2制备的MAX相涂层的XRD图谱。
实施例3:与实施例1不同的是,本对比例中的TiAl靶材的功率采用了115 W,经700℃退火处理后,涂层含有的Ti2AlC MAX相的含量达到88 wt%,还有微量的TiAl的结晶峰存在,腐蚀电流密度为4×10-10 A/cm2,结合力为73 N。
实施例4:与实施例1不同的是,本对比例中的TiAl靶材的功率采用了117 W,经700℃退火处理后,涂层含有的Ti2AlC MAX相的含量达到96 wt%,腐蚀电流密度为1×10-11 A/cm2,结合力为79 N。其中图5实施例4制备的MAX相涂层的XRD图谱。
对比例1:本实施例是上述实施例1的一个对比实施例。
(1)将基体依次用丙酮和酒精清洗,去除表面的油脂和可溶性杂质,放入腔体中。待真空度达到3.0×10-5 Pa以下,将样品转到离子束电源前,向腔通入33 sccm的氩气,设置离子束电源为1100 V,电流为0.2 A,打开挡板和离子束电源,设置偏压为-200 V,打开偏压电源,设置样品台自转,利用电离的氩离子清洗样品30 min。
(2) 停止样品台自转,并将样品台转到腔体门前,关掉离子束电源和挡板,关掉偏压电源,将Ar流量调整为200 sccm,打开电弧靶(Ti靶) Arc1和Arc3,不开挡板,设置电流为70 A,清洗5 min,调节腔体气压为15 mTorr,在直流电源功率为2000 W的条件下清洗Al靶5min。
(3) 镀过渡层。设置样品台转到Arc1和Arc3前并保持自转,镀上Ti过渡层,打开Arc1,设置偏压为80 V,电流为70 A,在15 mTorr压力条件下,镀膜10 min。镀TiC过渡层,不关闭Arc1,设置Ar流量为50 sccm,设置CH4为50 sccm,在15 mTorr气压下,镀膜10 min。
(4) 镀Ti-Al-C。设置Ar流量为200Sccm,CH4为20 sccm,偏压为-200 V,设置Arc3电流为60 A,设置Al靶对应的直流电源的功率为3200 W,打开Arc3和直流电源开关,关闭气压控制阀门,镀膜150 min。
(5) 将样品冷却至室温后取出,放入管式炉中,待真空度达到2.0×10-3 Pa以下,在加热速度为10 ℃/min,700 ℃温度条件下退火2 h
(6) 图6是对比例1的工艺制的涂层的扫描电镜图,表面存在明显的大颗粒缺陷。
(7) 图7为对比例1制得的Ti-Al-C系统的MAX相涂层的XRD图谱,说明涂层的主要相为Ti2AlC,还存在Ti3AlC2和TiC以及TiAl杂相,说明涂层相纯度较低,仅为55 wt%。
(8) 将样品封装制样放入到配置好的海水溶液中,作为腐蚀样品,图六的动电位极化图显示其腐蚀电流密度为2×10-9 A/cm2,相较于基体的8×10-8 A/cm2,说明其耐蚀性略优于基体,但明显没有实施例1的耐蚀性好。
(9) 对涂层进行划痕测试得到,涂层的膜基结合力为60 N。
对比例2:本实施例为上述实施例1的一个对比实施例。
本实施例与实施例1的区别仅在于:本实施例中没有TiAl层。经700 ℃退火后,得到的涂层的表面呈现鱼鳞状且相纯度仅为41 wt%,腐蚀电流密度为9×10-8 A/cm2,结合力为12 N。
对比例3:本实施例为上述实施例1的一个对比实施例。
本实施例与实施例1的区别仅在于:本实施例中腔体压强为0.4 Pa。经700 ℃退火后,得到的涂层边缘处略有剥落且相纯度仅为30 wt%,腐蚀电流密度为4×10-8 A/cm2,结合力为23 N。
对比例4:本实施例为上述实施例1的一个对比实施例。
本实施例与实施例1的区别仅在于:本实施例碳靶功率为100 W。经700 ℃退火后,得到的涂层Ti2AlC相纯度仅为35 wt%,腐蚀电流密度为6×10-8 A/cm2,结合力为52 N。
对比例5:本实施例为上述实施例1的一个对比实施例。
本实施例为钛合金基体样品,将镜面抛光好的钛合金基体样品分别用丙酮和乙醇依次清洗,以去除表面的杂质,然后制样放在海水溶液中作为腐蚀样品,图六的动电位极化图显示实施例1的腐蚀电流密度(2×10-11 A/cm2)明显低于对比例1(2×10-9 A/cm2)和对比例2(8×10-8 A/cm2)的腐蚀电流密度,说明本发明的耐蚀性优于对比例1和对比例5,且具有强的膜基结合力。
Claims (5)
1.一种强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,其特征在于,包括:
(1)选用TiAl合金作为靶材,氩气作为反应气体,采用高功率脉冲磁控溅射的方法在基体表面沉积TiAl涂层;
(2)然后打开C靶材,采用高功率脉冲磁控溅射和直流磁控技术共溅射方法在TiAl涂层表面沉积Ti-Al-C层;TiAl合金靶材是采用高功率脉冲磁控溅射方法,C靶采用直流磁控技术溅射;
(3)通过退火工艺使Ti-Al-C层发生固相反应转变为Ti2AlC MAX相防护涂层得到强结合高耐蚀TiAl/Ti2AlC涂层;
步骤(2)中,基体偏压为 -150-0 V,所述C靶功率为20-50 W;
所述TiAl涂层的厚度为0.5-1 μm;
所述退火工艺为:退火温度为600-900℃,时间为1-5 h;
步骤(1)中,所述TiAl合金靶材的功率为80-120 W,基体偏压为-150-0 V。
2.根据权利要求1所述的强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,其特征在于,所述基体包括TC4或不锈钢。
3.根据权利要求1所述的强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,其特征在于,步骤(1)中,所述TiAl合金靶材的功率为110-120 W,基体偏压为-100--50 V。
4.根据权利要求1所述的强结合高耐蚀TiAl/Ti2AlC涂层的制备方法,其特征在于,所述TiAl涂层为密排六方结构,元素原子比为Ti:Al=1-6:4,所述Ti-Al-C层厚度为3-7 μm,元素原子比为6:5:2-4:3:3。
5.根据权利要求1-4任一项所述的强结合高耐蚀TiAl/Ti2AlC涂层的制备方法制备的强结合高耐蚀TiAl/Ti2AlC涂层,其特征在于,所述TiAl/Ti2AlC涂层中的Ti2AlC MAX相的含量>83 wt.%。
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