CN115323346B - 一种重载轴承和齿轮表面的织构化涂层及制备方法 - Google Patents
一种重载轴承和齿轮表面的织构化涂层及制备方法 Download PDFInfo
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Abstract
本发明涉及一种重载轴承和齿轮表面的织构化涂层及制备方法,包括金属/金属化合物过渡层和硬质润滑层,所述金属/金属化合物过渡层位于金属基体表面,且所述金属/金属化合物过渡层表面具有亚微米级的凹坑,所述硬质润滑层位于所述金属/金属化合物过渡层表面,且具有亚微米级的凹坑。通过在传动零件表面制备含有亚微米级的凹坑的硬质润滑层,表面的亚微米级的凹坑在零件处于正常工况时起到储油、增加油膜厚度的作用,在极端工况时提供润滑、储存磨屑的作用,减缓了接触时的应力集中现象,有效提升薄膜寿命。同时硬质润滑层避免了金属间的直接接触,消除了基体表面或涂层外表面由加工引起的缺陷,保证了零件的表面完整性和可靠性。
Description
技术领域
本发明涉及表面处理与防护技术领域,特别是涉及一种重载轴承和齿轮表面的织构化涂层及制备方法。
背景技术
飞行器的传动系统通常在高速高载的情况下运行,在正常工况下,传动部件如齿轮或轴承间的接触面之间存在一层几微米厚的油膜,这种由弹流润滑形成的油膜几乎完全隔开了两个金属表面,在减小摩擦力的同时保护了接触金属表面。然而飞行器的翻滚等大幅度机动和瞬时过载会导致供传动系统中的部分零件处于乏油运行,在高载荷与乏油等极端状态的共同作用下,油膜无法形成,金属直接接触。重载下的金属直接接触可能导致局部的冷焊,进而发展成点蚀损伤,及进一步的疲劳失效。
当前针对重载乏油的传动零部件表面强化或改性技术包括渗碳渗氮增加金属表面硬度,降低点焊发生的可能性,参考专利CN110331260B一种重在齿轮渗碳淬火方法;以及采用真空等离子镀膜技术使用硬质自润滑涂层保护金属接触表面,杜绝金属间的接触,参考专利EP1290239B1。
当前针对重载乏油工况下齿轮、轴承表面的保护的各种技术都有着各自的不足。渗氮渗碳提升抗点蚀的表面强化方式,成本较低、对零件尺寸无影响,虽然能够一定程度提升零件抗冷焊、点蚀的能力,但是在重载和乏油的复合工况下,依旧难以杜绝金属表面的直接接触及进而引发的表面损伤。利用类金刚石等硬质润滑层保护传动零件隔开接触金属表面在乏油润滑时可以完全杜绝金属的直接接触,且自润滑类薄膜在固体与固体接触时可以提供一定的润滑效果,但是相比油膜0.05左右的摩擦系数,边界润滑0.15~0.3的摩擦系数仍旧偏高,在接触压力和切向摩擦力的共同作用下,薄膜与基底结合界面易出现破裂,导致薄膜剥落。
综合上所述,当前镀膜、表面织构以及两种方式复合虽然能够一定程度上降低极端工况下的零件损伤风险,但是都有各自缺点,有的甚至容易导致零件寿命的降低。
发明内容
为了解决在高载荷与乏油等极端状态的共同作用下,金属直接接触可能导致局部的冷焊,进而发展成点蚀损伤及进一步的疲劳失效的技术问题,第一方面,本发明实施例提供了一种重载轴承和齿轮表面的织构化涂层制备方法,包括步骤:S1将零件表面清洗晾干后放入真空室,抽真空后通入氩气,并打开离子源与零件偏压,对零件表面进行离子清洗,去除表面氧化物与有机物;S2使用阴极弧在沉积区表面沉积金属/金属化合物过渡层;S3待零件冷却后取出,在零件表面制备亚微米级的凹坑;S4将通过超声清洗的零件放入真空室,抽真空后对零件表面进行离子清洗,使用气体离子源或磁控溅射沉积硬质润滑层。
进一步地,所述S3包括步骤:(1)在零件表面制备单层纳米颗粒;(2)使用激光辐照纳米颗粒,纳米颗粒将激光聚焦后在纳米颗粒下方形成亚微米级的凹坑。
进一步地,步骤S3的(1)中,具体为:将玻璃基板依次用丙酮、酒精和去离子水清洗干净,然后放入25%的硝酸中浸泡24~36小时增加玻璃的亲水性;再将玻璃表面用离子水清洗晾干后,将二氧化硅悬浮液滴在玻璃表面,并在通风环境中保持9度的倾斜角晾干24~36小时后得到玻璃表面单层二氧化硅颗粒;在45微米厚聚丙烯薄膜表面涂覆聚烯烃树脂,并将涂覆面压在玻璃表面后将二氧化硅颗粒单层膜转移至聚丙烯薄膜表面,最后将薄膜覆盖在零件加工区域表面。
进一步地,步骤S3的(1)中,具体为:通过邻苯二甲酸二乙二醇二丙烯酸酯和氯化钠溶液制备的电解液浸泡零件使其表面改性带有正电荷;再泡入二氧化硅微球、水和乙醇混合得到的溶液,使二氧化硅颗粒均匀吸附在零件表面。
进一步地,步骤S3的(2)中,具体为:调整单脉冲功率密度,保证功率密度小于金属损伤阈值,并满足聚焦后可以融化金属制备凹坑;调整扫描速度,使相邻光斑之间搭接,光斑能够覆盖全部加工区域;保证入射激光垂直于加工区域表面,且与法向的夹角不大于10°。
进一步地,所述金属/金属化合物过渡层的厚度为3~10微米。
进一步地,所述硬质润滑层的厚度为1~3微米。
第二方面,本发明实施例提供了一种重载轴承和齿轮表面的织构化涂层,采用一种重载轴承和齿轮表面的织构化涂层制备方法制作,包括金属/金属化合物过渡层和硬质润滑层,所述金属/金属化合物过渡层位于金属基体表面,且所述金属/金属化合物过渡层表面具有亚微米级的凹坑,所述硬质润滑层位于所述金属/金属化合物过渡层表面,且具有亚微米级的凹坑。
综上,本发明通过在传动零件表面制备含有亚微米级的凹坑的硬质润滑层,表面的亚微米级的凹坑在零件处于正常工况时起到储油、增加油膜厚度的作用,在极端工况时提供润滑、储存磨屑的作用,减缓了接触时的应力集中现象,有效提升薄膜寿命。同时硬质润滑层避免了金属间的直接接触,消除了基体表面或涂层外表面由加工引起的缺陷,保证了零件的表面完整性和可靠性,提升了飞行器传动零件在极端工况下运行的可靠性。
附图说明
为了更清楚地说明本发明实施例的技术方案,下面将对本发明实施例中所需要使用的附图作简单地介绍,显而易见地,下面所描述的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1是一种重载轴承和齿轮表面的织构化涂层制备方法在制备亚微米级的凹坑的示意图;
图2是一种重载轴承和齿轮表面的织构化涂层的结构示意图;
图3是一种重载轴承和齿轮表面的织构化涂层的SEM图;
图中:1、金属/金属化合物过渡层;2、金属基体;3、二氧化硅颗粒;4、亚微米级的凹坑;5、硬质润滑层。
具体实施方式
下面结合附图和实施例对本发明的实施方式作进一步详细描述。以下实施例的详细描述和附图用于示例性地说明本发明的原理,但不能用来限制本发明的范围,即本发明不限于所描述的实施例,在不脱离本发明的精神的前提下覆盖了零件、部件和连接方式的任何修改、替换和改进。
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。下面将参照附图并结合实施例来详细说明本申请。
请参考图1~图3,第一方面,本发明实施例提供了一种重载轴承和齿轮表面的织构化涂层制备方法,包括步骤:
S1将零件表面清洗晾干后放入真空室,抽真空后通入氩气,并打开离子源与零件偏压,对零件表面进行离子清洗,去除表面氧化物与有机物。通过丙酮和酒精清洗去除表面油污,利用惰性气体离子对零件表面沉积区域进行轰击首先去除表面的有机物和金属氧化物,同时活化金属基体2表面,增大薄膜结合力。
S2使用阴极弧在沉积区表面沉积3~10微米厚的金属/金属化合物过渡层1提升薄膜整体结合力。通过在金属基体2表面沉积钛/氮化钛或铬/氮化铬等过渡层降低了类金刚石膜和其他金属基底由于热膨胀系数不一致导致的应力,同时在相对较软的金属如钛合金表面形成支撑层,使硬度逐渐过渡,减小由于硬度不匹配导致的接触应力集中,最终表现为提高薄膜结合力。
S3待零件冷却后取出,在零件表面制备亚微米级的凹坑4包括步骤:
(1)在零件表面制备单层纳米颗粒,可以用多种方法实现,例如:
a、转移膜法:将玻璃基板依次用丙酮、酒精和去离子水清洗干净,然后放入25%的硝酸中浸泡24小时增加玻璃的亲水性;再将玻璃表面用离子水清洗晾干后,将二氧化硅悬浮液滴在玻璃表面,并在通风环境中保持9度的倾斜角晾干24~36小时后得到玻璃表面单层二氧化硅颗粒3;在45微米厚聚丙烯薄膜表面涂覆聚烯烃树脂,并将涂覆面压在玻璃表面后将二氧化硅颗粒3单层膜转移至聚丙烯薄膜表面,最后将薄膜覆盖在零件加工区域表面。
b、二氧化硅颗粒表面自组装法:通过邻苯二甲酸二乙二醇二丙烯酸酯和氯化钠溶液制备的电解液浸泡零件使其表面改性带有正电荷;再泡入二氧化硅微球、水和乙醇混合得到的溶液,使二氧化硅颗粒3均匀吸附在零件表面,避免了薄膜转移法在双曲表面上的颗粒分布不均问题。
(2)使用激光辐照纳米颗粒,纳米颗粒将激光聚焦后在纳米颗粒下方形成亚微米级的凹坑4,具体为:调整单脉冲功率密度,保证功率密度小于金属损伤阈值,并满足聚焦后可以融化金属制备凹坑;调整扫描速度,使相邻光斑之间搭接,光斑能够覆盖全部加工区域;保证入射激光垂直于加工区域表面,且与法向的夹角不大于10°。
S4依次使用丙酮、酒精、去离子水超声清洗零件,去除残余二氧化硅颗粒3,将零件放入真空室,抽真空后对零件表面进行离子清洗,使用气体离子源或磁控溅射沉积1~3微米厚的硬质润滑层5,如金属掺杂的类金刚石薄膜等。此时硬质润滑层5表面包含过渡层加工的亚微米级的凹坑4结构,同时不存在加工导致的缺陷。
第二方面,本发明实施例提供了一种重载轴承和齿轮表面的织构化涂层,采用一种重载轴承和齿轮表面的织构化涂层制备方法制作,包括金属/金属化合物过渡层1和硬质润滑层5,所述金属/金属化合物过渡层1位于金属基体2表面,且所述金属/金属化合物过渡层1表面具有亚微米级的凹坑4,所述硬质润滑层5位于所述金属/金属化合物过渡层1表面,且具有亚微米级的凹坑4。由于在所述金属/金属化合物过渡层1表面具有亚微米级的凹坑4,在所述金属/金属化合物过渡层1表面上再沉积形成的所述硬质润滑层5,所述金属/金属化合物过渡层1表面的亚微米级的凹坑4形状也会体现在所述硬质润滑层5的表面。所述亚微米级的凹坑4的好处在于,其不仅有储存磨屑、润滑油的功能,由于其尺寸小、深度浅,引发的应力集中作用较小。同时增大金属/金属化合物过渡层1和硬质润滑层5界面的比表面积,提高了涂层结合力,同时保持了金属基体2的表面完整性,对金属基体2的疲劳性能影响可以忽略。
实施例1
在M50钢直齿轮齿面加工上述含织构涂层,具体操作步骤如下:
1、将齿轮依次放入丙酮、酒精中超声清洗15分钟去除表面油污,然后使用去离子水冲洗齿轮表面;晾干后放入真空室内,摆放时保证镀膜过程中齿轮可绕中心轴自转。
2、离子清洗:抽真空至压力小于8×10-3Pa,通入氩气流量150sccm,压力调节至1.0Pa,脉冲偏压1000V、占空比80%等离子清洗30分钟。
3、沉积Cr过渡层:氩气流量调整至150sccm,压力调节至1.0Pa,偏压电源120V、占空比80%,铬金属弧靶弧电流120A,稳弧电流1A,线圈频率6Hz,镀膜时间40min。
4、沉积CrN过渡层:氩气流量调整至50sccm,调整氮气流量100sccm,压力调节至1.0Pa,偏压电源120V,铬金属弧靶弧电流120A,稳弧电流1A,线圈频率6Hz,镀膜时间40min。
5、待零件在真空中冷却至室温取出。室温下,将零件置于表面改性电解质溶液中15分钟,取出后用去离子水冲洗零件,去除残留电解质溶液并采用氮气吹干。改性处理后,零件表面带有正电荷。上述表面改性电解质溶液配制方法:将PDDA(邻苯二甲酸二乙二醇二丙烯酸酯)浓度为4g/L、NaCl浓度为0.05mol/L充分混合。
6、将零件在配置好的SiO2悬浮液中浸泡30分钟后取出;SiO2微球悬浮液:将浓度为2.5%(W/V)的SiO2溶液与无水乙醇按体积比为1:30进行稀释得到分散均匀的SiO2溶液,本实例中使用SiO2微球直径为900nm。
7、使用超快激光扫描直尺齿面,光束尽量与加工表面局部垂直,倾角不大于10度。激光参数:波长513nm,加工速度380mm/s,重复频率1000Hz,脉宽190fs,单脉冲能量密度150mJ/cm2,此处加工速度较低为保证相邻脉冲光斑之间有搭接,均匀制备表面结构。
8、清洗残余SiO2颗粒:依次采用丙酮、酒精、去离子水超声清洗零件15分钟。
9、沉积类金刚石薄膜:将齿轮晾干后再次放入真空室内,保证摆放时保证镀膜过程中齿轮可绕中心轴自传。抽真空至压力小于8×10-3Pa,通入氩气流量150sccm,压力调节至1.0Pa,脉冲偏压1000V、占空比80%等离子清洗30分钟。调整氩气流量至50sccm,氮气流量25sccm,乙炔流量25sccm,压力调节至1.0Pa,偏压电源120V,碳中频磁控靶电流12A,碳化钨中频磁控靶电流调节至1A,镀膜时间240分钟。
在传动零件表面制备含有亚微米级的凹坑4的硬质润滑层5,表面的亚微米级的凹坑4在零件处于正常工况时起到储油、增加油膜厚度的作用,在极端工况时提供润滑、储存磨屑的作用,减缓了接触时的应力集中现象,有效提升薄膜寿命。同时硬质润滑层5避免了金属间的直接接触,消除了基体表面或涂层外表面由加工引起的缺陷,保证了零件的表面完整性和可靠性,提升了飞行器传动零件在极端工况下运行的可靠性。
需要明确的是,本说明书中的各个实施例均采用递进的方式描述,各个实施例之间相同或相似的部分互相参见即可,每个实施例重点说明的都是与其他实施例的不同之处。对于方法的实施例而言,相关之处可参见设备实施例的部分说明。本发明并不局限于上文所描述并在图中示出的特定步骤和结构。并且,为了简明起见,这里省略对已知方法技术的详细描述。
以上所述仅为本申请的实施例而已,并不限制于本申请。在不脱离本发明的范围的情况下对于本领域技术人员来说,本申请可以有各种更改和变化。凡在本申请的精神和原理之内所作的任何修改、等同替换、改进等,均应包含在本申请的权利要求范围内。
Claims (7)
1.一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,用于制作重载轴承和齿轮表面的织构化涂层,所述织构化涂层包括金属/金属化合物过渡层和硬质润滑层,所述金属/金属化合物过渡层位于金属基体表面,且所述金属/金属化合物过渡层表面具有亚微米级的凹坑,所述硬质润滑层位于所述金属/金属化合物过渡层表面,且具有亚微米级的凹坑;
所述方法包括步骤:
S1将零件表面清洗晾干后放入真空室,抽真空后通入氩气,并打开离子源与零件偏压,对零件表面进行离子清洗,去除表面氧化物与有机物;
S2使用阴极弧在沉积区表面沉积金属/金属化合物过渡层;
S3待零件冷却后取出,在零件表面制备亚微米级的凹坑;
S4将通过超声清洗的零件放入真空室,抽真空后对零件表面进行离子清洗,使用气体离子源或磁控溅射沉积硬质润滑层。
2.根据权利要求1所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,所述S3包括步骤:
(1)在零件表面制备单层纳米颗粒;
(2)使用激光辐照纳米颗粒,纳米颗粒将激光聚焦后在纳米颗粒下方形成亚微米级的凹坑。
3.根据权利要求2所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,步骤S3的(1)中,具体为:
将玻璃基板依次用丙酮、酒精和去离子水清洗干净,然后放入25%的硝酸中浸泡24~36小时增加玻璃的亲水性;
再将玻璃表面用离子水清洗晾干后,将二氧化硅悬浮液滴在玻璃表面,并在通风环境中保持9度的倾斜角晾干24~36小时后得到玻璃表面单层二氧化硅颗粒;
在45微米厚聚丙烯薄膜表面涂覆聚烯烃树脂,并将涂覆面压在玻璃表面后将二氧化硅颗粒单层膜转移至聚丙烯薄膜表面,最后将薄膜覆盖在零件加工区域表面。
4.根据权利要求2所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,步骤S3的(1)中,具体为:
通过邻苯二甲酸二乙二醇二丙烯酸酯和氯化钠溶液制备的电解液浸泡零件使其表面改性带有正电荷;
再泡入二氧化硅微球、水和乙醇混合得到的溶液,使二氧化硅颗粒均匀吸附在零件表面。
5.根据权利要求2所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,步骤S3的(2)中,具体为:
调整单脉冲功率密度,保证功率密度小于金属损伤阈值,并满足聚焦后可以融化金属制备凹坑;
调整扫描速度,使相邻光斑之间搭接,光斑能够覆盖全部加工区域;
保证入射激光垂直于加工区域表面,且与法向的夹角不大于10°。
6.根据权利要求1所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,所述金属/金属化合物过渡层的厚度为3~10微米。
7.根据权利要求1所述的一种重载轴承和齿轮表面的织构化涂层制备方法,其特征在于,所述硬质润滑层的厚度为1~3微米。
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CN105858594A (zh) * | 2016-04-15 | 2016-08-17 | 清华大学 | 钢结构的表面加工方法 |
CN107237821A (zh) * | 2017-06-27 | 2017-10-10 | 江苏大学 | 一种航空发动机轴承的自润滑处理方法 |
CN111570554A (zh) * | 2020-04-30 | 2020-08-25 | 江苏大学 | 一种齿轮冷挤压模具织构化涂层自润滑方法 |
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