CN117488232A - 一种镍硅或氮化硼可磨耗封严涂层及其制备方法 - Google Patents
一种镍硅或氮化硼可磨耗封严涂层及其制备方法 Download PDFInfo
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Abstract
一种镍硅或氮化硼可磨耗封严涂层，镍硅或氮化硼粉末为致密团聚的复合粉末，其结构为镍硅中间体、超细铝粉做为骨架结构，形成规则的类球状颗粒结构。镍硅或氮化硼粉末中按质量百分比，BN为5.0~11.0%，Al含量为0.2~1.0%，C含量为1.0~2.0%，SiO2含量为4.0~11.0%，Ni为余量。制备方法：采用Φ10mm的钢球在250kg载荷下保持60s，压痕直径应为Φ3.8mm‑Φ6.3mm；涂层结合强度应≥4MPa。投入冷水中淬冷，涂层无剥落和分层。本发明优点：消除了沉积在涂层表面的大颗粒，提高了涂层质量，并减少了原材料制备成本。实现自动化喷涂，提高了涂层的稳定性，缩短了零件加工工时，减少了人工成本。涂层制备方法流程简单，生产成本低，适合批量生产，具有广阔的应用前景。
Description
技术领域
本发明涉及航空发动机涂层材料技术领域，特别涉及一种镍硅或氮化硼可磨耗封严涂层及其制备方法。
背景技术
可磨耗封严涂层是航空发动机上一种重要的功能性涂层。该类涂层通常制备在涡轮机或压气机等固定件上，在与旋转件相互接触工作时，发生磨损消耗，使旋转件更好地贴合在涂层内部，进而改善旋转件与固定件之间的密封性，提高发动机的推重比及运行效率。一般而言，可磨耗封严涂层由金属骨架相（如铜、铝、硅等）与高孔隙率的非金属相（镍石墨、聚苯酯、硅藻土等）组成，其中金属相保证涂层的热稳定性、抗冲蚀性以及与基体的结合性，非金属相发挥涂层的减磨、抗黏着、自润滑性。
某型号发动机封严环上要求制备镍硅或氮化硼涂层，通过与篦齿零件对磨实现封严效果。目前涂层通过火焰喷涂镍硅或氮化硼棒料制备，该工艺为80年代引进，主要原理是通过氧、乙炔将棒料加热熔化，经压缩空气雾化后喷涂至零件表面。原材料制备工艺复杂，成分均匀性差。喷涂过程中会有未熔化的大颗粒飞溅到涂层表面，需人工识别并及时清理。制粉及喷涂工艺老旧，流程复杂，且由于无法实现自动化，生产效率极低，涂层质量不稳定。
发明内容
本发明的目的是通过自动化等离子喷涂粉末工艺代替原有手工火焰喷涂棒料工艺，获得镍硅或氮化硼涂层。从而提高生产效率，解决质量不稳定的问题。
本发明提供了一种镍硅或氮化硼可磨耗封严涂层，其特征在于：
镍硅或氮化硼粉末为致密团聚的复合粉末，其结构为镍硅中间体、超细铝粉做为骨架结构，在水玻璃粘结剂作用下紧密包覆氮化硼、镍包石墨粉末，形成规则的类球状颗粒结构。
镍硅或氮化硼粉末中按质量百分比，BN为5.0~11.0%，Al含量为0.2~1.0%，C含量为1.0~2.0%，SiO2含量为4.0~11.0%，Ni为余量。
镍硅或氮化硼粒度分布质量百分比为+50目≤5%，-50目~ +325目≥80%，-325目≤15%。
镍硅或氮化硼涂层与金属零件基体材料成分差异较大，不能单独使用，为了保证其与基体的结合效果，需要在工件表面制备一层与基体和镍硅或氮化硼涂层膨胀系数相近的涂层，设计了基体+过渡层+合金涂层的应用结构，过渡层为自粘结的镍铝涂层。
为了保证镍硅或氮化硼涂层发挥封严的作用效果，且能够长期稳定使用，需要将涂层的结合强度、硬度和抗热震性控制到一定范围。涂层的硬度应适中，硬度过高会损伤对磨篦齿，硬度太低影响涂层自身内聚力及与基体的结合强度，工作中容易剥落、掉块。此外，航空发动机服役工况严苛，涂层会在冷热交替下工作，因此需要具备一定的抗热震能力。
采用布氏硬度机测量，采用Φ10mm的钢球在250kg载荷下保持60s，压痕直径应为Φ3.8mm-Φ6.3mm。涂层结合强度应≥4MPa。在500℃±10℃下保温2min，投入冷水中淬冷，至少反复5次，涂层无剥落和分层。
涂层采用自动化等离子喷涂方式制备，机械手夹持喷枪，运行程序与喷涂设备联动，一键启动。涂层性能控制可通过大气等离子喷涂工艺技术和过程控制来实现。
本发明与现有技术相比，其优点在于：
本发明所述的镍硅或氮化硼可磨耗封严涂层及其制备方法，通过喷涂粉末代替棒材，消除了沉积在涂层表面的大颗粒，提高了涂层质量，并减少了原材料制备成本。此外，涂层实现了自动化喷涂，提高了涂层的稳定性，缩短了零件加工工时，减少了人工成本。涂层制备方法流程简单，操作方便，生产成本低，适合批量生产，具有广阔的应用前景。
附图说明
下面结合附图及实施方式对本发明作进一步详细的说明：
图1为镍硅或氮化硼粉末形貌；
图2为镍硅或氮化硼面层显微组织示意图。
具体实施方式
下面将结合具体的实施方案对本发明进行进一步的解释，但并不局限本发明，说明书附图所绘示的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容所能涵盖的范围内。
一种用于航空发动机的Ni-BN可磨耗封严涂层制备具体实施方式如下：
（1）将镍铝和镍硅或氮化硼粉末分别平铺在带盖的托盘，在温度设定为60℃烘箱内烘干，时间为1h，烘干后的粉末在使用前存放于烘箱内或其他干燥容器内，使用之前粉末在容器内混合搅拌15 min。粉末形貌见图1。
（2）用脱脂棉或毛刷蘸丙酮对零件的喷涂区域及相邻区域进行仔细地擦拭清洗，彻底除去零件表面上的油污。用压缩空气吹干，戴干净的手套接触零件，避免造成零件二次污染。
（3）对非喷涂区采用工装或压敏胶带进行保护，确认保护有效后，采用压力式吹砂机进行吹砂，吹砂风压0.40 MPa，吹砂距离130 mm，吹砂角度为75°。吹砂后用清洁的压缩空气吹除吹砂后零件表面的浮灰。
（4）使用UNICOAT等离子喷涂设备制备涂层，喷枪为F4型，电极直径为6 mm。使用喷枪对零件进行预热，预热温度为80～100℃。吹砂及各涂层喷涂时间间隔均不得超过2 h，每次喷涂前需采用压缩空气清理喷涂区。
（5）喷涂镍铝底层，电流为520 A，氩气流量为55 NLPM，氢气流量为12 NLPM，送粉速率为30 g/min，喷涂距离为130 mm，喷涂角度为90。喷涂涂层厚度为0.12 mm。
（6）喷涂镍硅或氮化硼面层，电流为400 A，氩气流量为45 NLPM，氢气流量为6NLPM，送粉速率为30 g/min，喷涂距离为130 mm，喷涂角度为90。喷涂涂层厚度为2.5 mm。
喷涂结束后，测得涂层压痕直径为4.90mm，涂层拉伸结合强度为7.4 MPa，其中面层显微组织如图2所示。经500℃水冷循环10次后，涂层无剥落、分层现象。
本发明未尽事宜为公知技术。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (3)
1.一种镍硅或氮化硼可磨耗封严涂层，其特征在于：
镍硅或氮化硼粉末为致密团聚的复合粉末，其结构为镍硅中间体、超细铝粉做为骨架结构，在水玻璃粘结剂作用下紧密包覆氮化硼、镍包石墨粉末，形成规则的类球状颗粒结构；
镍硅或氮化硼粉末中按质量百分比，BN为5.0~11.0%，Al含量为0.2~1.0%，C含量为1.0~2.0%，SiO2含量为4.0~11.0%，Ni为余量；
镍硅或氮化硼粒度分布质量百分比为+50目≤5%，-50目~ +325目≥80%，-325目≤15%。
2.一种如权利要求1所述的镍硅或氮化硼可磨耗封严涂层的其制备方法，其特征在于：设计了基体+过渡层+合金涂层的应用结构，过渡层为自粘结的镍铝涂层；
为了保证镍硅或氮化硼涂层发挥封严的作用效果，且能够长期稳定使用，需要将涂层的结合强度、硬度和抗热震性控制到一定范围；涂层的硬度应适中，硬度过高会损伤对磨篦齿，硬度太低影响涂层自身内聚力及与基体的结合强度，工作中容易剥落、掉块；此外，航空发动机服役工况严苛，涂层会在冷热交替下工作，因此需要具备一定的抗热震能力；
采用布氏硬度机测量，采用Φ10mm的钢球在250kg载荷下保持60s，压痕直径应为Φ3.8mm-Φ6.3mm；涂层结合强度应≥4MPa；在500℃±10℃下保温2min，投入冷水中淬冷，至少反复5次，涂层无剥落和分层。
3.根据权利要求2所述的镍硅或氮化硼可磨耗封严涂层及其制备方法，其特征在于：涂层采用自动化等离子喷涂方式制备，机械手夹持喷枪，运行程序与喷涂设备联动，一键启动；涂层性能控制通过大气等离子喷涂工艺技术和过程控制来实现。
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