梯度层不同配比对等离子喷涂Mo/8YSZ功能梯度热障涂层残余应力的影响规律研究

传统的金属/陶瓷双层热障涂层因不同涂层热物性参数的差异,易在涂层内部产生过大的残余应力,影响涂层质量及可靠性,而采用梯度结构的热障涂层,可实现涂层厚度方向热物性参数的连续平滑过渡,从而减小涂层间的残余应力,提升涂层的可靠性。梯度层配比不同,将使得涂层残余应力的分布情况及数值大小不同,为了研究不同梯度层配比对Mo/8YSZ功能梯度热障涂层残余应力的影响规律,利用ANSYS有限元分析软件建立了等离子喷涂Mo/8YSZ双层热障涂层及功能梯度热障涂层的数值模型,并在模型中考虑了材料热物性参数随温度变化,对比传统双层热障涂层,分析了不同梯度层配比对喷涂构件残余应力数值大小及分布区域的影响规律。结果表明:在喷涂参数相同的情况下,功能梯度热障涂层系统相比于双层热障涂层系统,径向最大残余拉应力与压应力均增大,轴向最大残余应力减小;伴随着过渡层第一层Mo比例的增加,喷涂构件的最大轴向残余拉应力增大,喷涂构件的最大轴向残余压应力减小;伴随着过渡层第一层Mo含量的增大,基体与涂层界面拉应力的分布区域增大,压应力的分布区域减小;采用功能梯度热障涂层结构,由于缓和了不同种类涂层间热物性参数的差异,可显著改善喷涂构件轴向的应力突变情况。     

应力释放槽对等离子喷涂Mo/8YSZ热障涂层残余应力的影响规律研究

为了突破传统双层热障涂层高温易剥离的技术瓶颈,在喷涂构件基体边缘开设应力释放槽,基于热弹塑性有限元理论,利用ANSYS有限元仿真模拟软件,建立了基于应力释放槽结构的等离子喷涂Mo/8YSZ热障涂层的数值模型,模型中考虑了材料不同温度下的热物性参数,研究了喷涂构件基体边缘不同开槽位置对热障涂层残余应力的影响规律。结果表明:改变应力释放槽的位置对基体与涂层界面边缘区域(0～2.4 mm)的径向残余应力影响更为明显;随着应力释放槽与基体和涂层界面距离的增加,基体与涂层界面同一位置的径向残余压应力逐渐减小;随着应力释放槽与基体和涂层界面距离的增加,基体与涂层界面同一位置的轴向残余拉应力逐渐减小;当应力释放槽与基体和涂层界面的距离增加至1.2 mm时,随着应力释放槽与基体和涂层界面距离的增加,轴向残余拉应力变化不明显。通过在喷涂构件基体边缘开设应力释放槽,可减小基体与涂层界面的残余应力。     

冷却方式对等离子喷涂Mo/8YSZ热障涂层残余应力的影响规律研究

为了研究冷却方式对等离子喷涂热障涂层残余应力的影响规律,基于热弹塑性有限元理论,并利用ANSYS有限元软件,建立了等离子喷涂Mo/8YSZ热障涂层的数值模型,模型中考虑了材料不同温度下的热物性参数,研究了在同步冷却和滞后冷却两种冷却方式下喷涂构件残余应力的分布情况及变化趋势。结果表明:伴随着对流换热系数的增加,喷涂构件的最大径向残余拉应力逐渐减小,而最大径向残余压应力呈现先减小后增大的变化趋势;采用空气自然冷却、压缩空气冷却或静水冷却的方式对喷涂构件进行冷却处理时,喷涂构件的最大轴向残余拉应力小于最大轴向残余压应力,当采用循环水冷却时,喷涂构件的轴向残余拉应力大于轴向残余压应力;伴随着滞后冷却时间间隔的增加,喷涂构件的最大轴向残余拉应力增大,最大轴向残余压应力减小,最大径向残余应力与最大剪残余应力的变化不明显;当滞后冷却时间间隔在0～60 s范围时,喷涂构件残余应力影响变化不明显;涂层剥离失效的大概率位置位于相异涂层界面或基体与涂层界面下方0.2～0.4 mm区间范围内,且伴随着滞后冷却时间间隔的增加及对流换热系数的增加,涂层缺陷的萌发位置逐渐向界面边缘转移。通过合理调控等离子喷涂作业的冷却方式,可实现喷涂构件的残余应力合理分布,进一步提升基体与涂层的结合强度。     

超音速火焰喷涂含铝或锌中间层的YSZ热障涂层

在镁合金基底表面直接制备热障涂层,涂层的耐蚀性较差。采用超音速火焰喷涂法在镁合金基底和热障涂层之间分别制备了Al涂层和Zn涂层。通过XRD,SEM和EDS对涂层进行物相、微观结构和点扫描元素分析,采用电化学工作站对Al涂层试样和Zn涂层试样进行耐腐蚀性分析,同时研究了含Al中间层和含Zn中间层的热障涂层的抗热震性能。结果表明:Al涂层表面粗糙度(10.237±0.527μm)大于Zn涂层表面粗糙度(7.171±0.488μm),且喷涂过程中仅有轻微氧化。Al涂层试样的耐腐蚀性优于Zn涂层试样。含Zn中间层的热障涂层具有更好的抗热震性能。     

CeO2对等离子喷涂Cr2O3涂层抗热震性的影响

在Ｃｒ２Ｏ３陶瓷粉末中添加不同量的ＣｅＯ２,探讨ＣｅＯ２对等离子喷涂涂层抗热震性的影响,认为涂层的热震失效机制是在循环应力作用下发生在陶瓷层／粘结层界面的疲劳失效。在等离子喷涂Ｃｒ２Ｏ３涂层中添加３％ＣｅＯ２后,热震超裂寿命及失效寿命均得到明显提高。适量的ＣｅＯ２使微型裂纹呈现网状分布于涂层薄片内,具有释放涂层内应力的作用,可延缓裂纹的起裂和扩展,并使涂层内贯穿性孔洞减少,从而显著提高涂层的抗热震     

碳钢低压冷喷涂铝涂层的海水耐蚀性

本文以Al和10%体积比Al2O3的混合粉末为原料,使用便携式低压冷喷涂设备,在Q235碳钢基体上喷涂了Al涂层. 测试涂层自腐蚀电位及动电位极化曲线,结合扫描电镜观察涂层表面及截面微观形貌,研究了低压冷喷涂Al涂层在海水中电化学腐蚀行为,并与高压冷喷涂和热喷涂铝涂层的耐蚀性比较. 结果表明,低压冷喷涂铝涂层结构较为致密,其耐蚀性比高压冷喷涂铝涂层的略低,而明显优于热喷涂铝涂层.     

纳米结构(Gd0.9Yb0.1)2Zr2O7/YSZ热障涂层热冲击性能研究

航空发动机的高推重比、高效率对热障涂层材料和结构提出了更高要求。利用同步双送粉系统制备了纳米(Gd_0.9Yb_0.1)₂Zr₂O₇/YSZ双陶瓷层结构和准梯度复合结构的热障涂层,对其在1350～1400℃的火焰热冲击性能与失效机制进行了分析。结果表明：(Gd_0.9Yb_0.1)₂Zr₂O₇(GY-bZ)热障涂层显示出较好的高温相结构稳定性,其喷涂态与热冲击失效后都是单一的萤石结构;GYbZ/YSZ热障涂层是由纳米未熔颗粒和熔化结晶区组成的“双模式”结构;GYbZ/YSZ双层结构涂层的热冲击寿命为113次,GYbZ/YSZ准梯度结构涂层的热冲击寿命达到370次;双层结构涂层的剥落主要发生在GYbZ内部以及GYbZ与YSZ的层间界面,而准梯度结构涂层的剥落则发生在热生长氧化物(TGOs)附近的YSZ层内。准梯度结构和纳米“双模式”结构相结合是提高热障涂层高温使役性能的有效方法。     

气膜孔冷却气流量对等离子喷涂涂层堵孔率及YSZ涂层性能的影响

在等离子喷涂制备涂层的过程中,涂层对气膜孔造成堵塞,影响冷却效果和热障涂层的寿命。通过向带气孔的高温合金基体的背部通入压缩空气,来降低涂层对气膜孔的堵塞作用。采用扫描电镜和X射线衍射对气膜孔的堵塞率和气膜孔周围YSZ涂层的相组成进行了分析,同时研究了气膜孔冷却气流量对涂层热循环寿命的影响。结果表明:随着气膜孔冷却气流量的增加,气膜孔堵塞率明显降低,涂层孔隙率、 t′相以及热循环寿命逐渐增加。然而,当气膜孔冷却气流量过大时(≥8.0m~3·h~(-1)),涂层的热震寿命降低。气膜孔冷却气流量为6.5 m~3·h~(-1),可制备出t′相含量高、孔隙率较大、堵孔率较低和热循环寿命长的涂层。     

喷涂法构筑二氧化硅纳米粒子涂层及其光学和润湿性质

采用Stöber方法,通过调节反应温度及乙醇和水的体积,合成了不同粒径的二氧化硅纳米粒子.以合成的粒径为20 nm的二氧化硅纳米粒子为原料,采用简单、方便的喷涂方法在玻璃片上构筑了纳米粒子涂层.在550 ℃煅烧二氧化硅纳米粒子涂层,增强了二氧化硅纳米粒子在玻璃片上的附着力.用1H, 1H, 2H, 2H-全氟辛基三乙氧基硅烷修饰之后,二氧化硅纳米粒子涂层的表面润湿性由亲水性转变为疏水性.通过喷涂法制备的二氧化硅纳米粒子涂层具有减反增透效果,当二氧化硅纳米粒子质量分数为0.48%、循环喷涂沉积数为3时,涂层在可见光范围内的最大透光率可达95.5%.用扫描电子显微镜观测涂层表面形貌发现,喷涂法制备的涂层是均匀的、可控的.喷涂技术构筑纳米粒子涂层具有简单快速、可大面积应用等优点.     

喷涂法制备功能性超疏水复合涂层及其性能研究

以常用工程材料硅树脂BP与St(o)ber法合成的二氧化硅(SiO2)分散液为原料,运用喷涂法(spray-coating)制备出了功能性微/纳粗糙(MNR)结构的超疏水涂层,其接触角可以达到146.5°,滚动角小于1°(测试液滴量为15μL).通过分析喷涂法制备复合涂层所需的条件,得出喷涂液pH＝7.7-8.0时,在...     

Resistance of zinc thermal sprayed coatings on different corrosive environments

Zinc coatings on ferrous substrates are possible to be applied with thermal spraying. In the present work the corrosion behavior of zinc thermal sprayed coatings deposited on low carbon steel St-37 was examined in a simulated marine atmosphere (salt spray chamber-SSC) and in a dry atmosphere at elevated temperature (400°C). The corrosion progress was examined by means of optical microscopy, scanning electron microscopy, X-ray diffraction and thermogravimetric analysis. From this investigation it was deduced that in the SSC the coating is uniformly corroded, while the main corrosion products are hydrated zinc oxides and chlorides. By contrast at 400°C only a thin, compact and continuous film of ZnO is formed on top of the coating, which remains adherent to the ferrous substrate.     

不同色浆质量分数的水性聚氨酯涂料对聚氯乙烯表皮低温爆破性能的影响

本文制备了一系列不同色浆质量分数的水性聚氨酯涂料,并将其喷涂在汽车仪表板聚氯乙烯(PVC)表皮的背面形成复合材料。 用旋转流变仪表征了涂料的粘度以评价其喷涂性能;用差示扫描量热仪表征了材料的玻璃化转变温度(T_g);利用万能材料试验机表征了材料在-30 ℃条件下的拉伸性能及抗撕裂性能;用动态热机械分析仪表征了材料的损耗比随温度的变化。 结果表明:不同色浆质量分数的涂料都能喷涂,含有涂层材料PVC表皮在-30 ℃低温爆破性能与涂层材料的T_g、低温拉伸性能、抗撕裂性能的关系并不大,而与涂层材料的阻尼性能直接相关。 材料的阻尼性能越好,其低温爆破性能越好。     

Tribological evaluation of HVOF thermal‐spray coatings as a hard chrome replacement

Hard chrome plating has been used in several different applications in industries that require abrasive sliding wear resistance, such as hydraulic pistons, shafts or bearings. However, the increasing environmental and worker safety pressures on electrolytic hard chrome are leading companies to adopt alternatives. The improvements of the high‐velocity‐oxy‐fuel (HVOF) thermal spray process allow the chromium coating replacement with a comparable or superior surface treatment and are more environmentally friendly. This HVOF process, as a flexible dry‐coating technology, avoids high‐volume waste streams and enables a flexible choice of coating material for each application. The cobalt–chromium‐cemented tungsten carbides are some of the easiest materials to spray and the WC‐10Co‐4Cr coatings have demonstrated superior performance over hard chrome with regard to mechanical and tribological properties. In this work, this coating has been deposited with a Sulzer Metco WokaJet‐400 kerosene fuel spray gun, and the spray conditions have been optimized in order to ensure the best properties of the coatings. The mechanical and tribological properties have been evaluated in coatings sprayed with four deposition conditions that involve different gas flow rates. The most wear‐resistant coating is obtained with those HVOF parameters that prevent decarburization of WC particles and, at the same time, allow an adequate agglomerate melting giving a good intersplat adhesion. The results indicate that HVOF‐sprayed WC‐CoCr coatings are a reliable alternative to electrolytic hard chrome (EHC) in the aeronautical industry to coat landing gear components. In particular, in the dry wear tests, the WC‐CoCr coatings outperform hard chrome coatings in wear resistance. Copyright © 2010 John Wiley & Sons, Ltd.     

Microstructure and surface residual stress of plasma sprayed nanostructured and conventional ZrO2‐8wt%Y2O3 thermal barrier coatings

The nanostructured agglomerate feedstock which can be used for plasma spraying was obtained successfully by the reconstituting nanoparticle technique. Nanostructured and conventional ZrO₂‐8wt%Y₂O₃ (8YSZ) thermal barrier coatings (TBCs) have been prepared by atmospheric plasma spraying (APS) on NiCoCrAlY coated 45# steel substrates. The microstructure and phase composition of feedstock and corresponding coating were characterized by SEM and XRD. The elastic modulus was tested by the nanoindenter instrument. The surface residual stresses were examined by XRD stress test equipment. The numerical value probability statistics of surface residual stress by the Weibull distribution theory was implemented under different thermal spray parameters. The value of residual stresses increased with increasing the thickness of the ceramic coating. The surface residual stress of nanostructured 8YSZ coating is lower than that of the conventional 8YSZ coating. A physical mechanical model is put forward to explain the causation of the variation of residual stresses. At the same time, the variation characteristic of surface residual stress is discussed by introducing the closed form solution of residual stress of laminar layer plate. Copyright © 2010 John Wiley & Sons, Ltd.     

六种添加剂对烟丝挥发性与半挥发性成分含量的影响

分别配制1%(质量分数,下同)的柠檬酸、苹果酸、乳酸水溶液以及5%的(NH4)2HPO4、K2CO3、柠檬酸钾水溶液.分别取100.0g烟丝,均匀喷洒10.0mL上述水溶液,经平衡、实验室模拟烘丝、萃取后,进行气相色谱-质谱测定,分析烟丝中挥发性和半挥发性香味成分含量的变化.结果表明,喷洒柠檬酸和K2CO3水溶液可显著改变烟丝的化学成分含量.烟丝经K2CO3水溶液喷洒后,游离态的尼古丁含量大幅增加,醇类组分、巨豆三烯酮含量有所升高,酸类组分和酯类组分含量略有降低;而经柠檬酸水溶液喷洒后的烟丝的酸类、醇类和酯类组分含量升高,尼古丁含量下降.     

Surface characterization of plasma sprayed oxide materials: estimation of surface acidity using mass titration

The aim of this study was to characterize the influence of plasma spraying on the point of zero charge (PZC) of Al2O3-, Cr2O3- and TiO2-based materials. PZC is one of the most important parameter, which describes the acidity of oxide material in aqueous environments. PZC values of several plasma sprayed oxides were determined using mass titration method. Studies were performed for initial spray powders and plasma sprayed coating materials. In addition, mass titration experiments were performed for water-washed and nonwashed samples. It was found that mass titration is a suitable method to estimate the surface acidity of relatively coarse sample powders. It was found for most of the studied materials that the limiting pH values (assumed to be close PZC) were close to those reported in literature for the PZC values of traditionally manufactured oxide materials. On the other hand, mass titration curves of some oxide samples showed unexpected deviation in curve shapes and limiting pH. These deviations were probably due to selective dissolution of sample contaminations or sample material.     

Melting Refining Mechanisms in Supersonic Atmospheric Plasma Spraying

In recent years, Yttria-stabilized zirconia based thermal barrier coatings (TBCs) are deposited by newly-developed high-efficiency supersonic atmospheric plasma spraying (SAPS) technology. The final microstructure of the plasma-sprayed coatings is strongly dependent on the size distribution of spray particles. It has been corroborated through experiments that there is a special phenomenon of particle melting refining in SAPS, as compared with the conventional atmospheric plasma spraying (APS). This phenomenon greatly affects the final particle size and distribution, which has not been explained reasonably up to now. Therefore, it is necessary to investigate the melting refining behavior of in-flight particles to control the particle size and to analyze the coating properties. In this paper, the breakup of particle is presented to characterize the phenomenon of particle melting refining, and the peak of size distribution becomes bigger with increasing the spray distances, which is explained by collision-coalescence. Furthermore, based on the maximum entropy formalism, the particle-size distribution is calculated and the result is in good accordance with the plasma spraying experiment results, which verifies the mechanism analysis presented in this paper. This work could provide more efficient applications of the SAPS technology in high-performance TBCs.     

Numerical simulation of film coating process in a novel rotating fluidized bed

In this study, numerical simulation of film coating process in a novel rotating fluidized bed (RFB) was conducted by using a Discrete Element Method (DEM)-Computational Fluid Dynamics (CFD) coupling model. Particle movements and fluid motions in a centrifugal force field were simulated at three-dimensional cylindrical coordinate, and this model was applied to film coating process. Film coating process in a RFB was numerically analyzed by using a simplified assumption that a particle was coated only when a particle existed within a spray zone. The experiments were also conducted and uniformity of sprayed material was evaluated by investigating color difference of the coated particles. As a result of the numerical simulation, three-dimensional bubble movements and particle circulation could be well simulated. In addition, mass of the sprayed material on a single particle in a RFB could be visualized by using our proposed model. The relationship between distribution of the sprayed material and the coating time was also analyzed. Calculated mass distributions of the sprayed material could be expressed by a normal distribution function, showing qualitative good agreement with the previous studies. Effect of the operating parameters, such as gas velocity and centrifugal acceleration, on the uniformity of the sprayed material was also investigated by both numerical and experimental approaches. Comparison of the coating process in a RFB with that in a conventional fluidized bed was also conducted by the numerical simulation. The result showed that uniformity of the sprayed material was greatly improved in a RFB due to the much smaller circulation time.