激光熔覆Al+SiC涂层对镁合金表面耐磨性能的改性

通过脉冲激光器(Nd-YAG)在AZ91D镁合金基底上熔覆Al+SiC粉体。采用扫描电子显微镜、能量色散谱(EDS)和X-射线衍射测定分析熔覆层的显微组织、化学成分和物相组成。研究表明:Al+SiC涂层主要由SiC,β-Mg_(17)Al_(12)及Mg和Al相组成,激光熔覆层与镁合金基底表现出良好的冶金结合。所有样品都具有树枝状结构,且随着SiC质量分数的增大,树枝状和胞状结构的间隔变得更大。熔覆涂层的表面硬度高于基底,并且随着熔覆层中的SiC质量分数的增加而增大,SiC质量分数为40%的熔覆层具有最大的显微硬度,达到180 HV,然而质量分数为10%的熔覆层硬度为136 HV。销盘滑动磨损试验表明,复合涂层中的SiC颗粒和原位合成的Mg_(17)Al_(12)相显著提高了AZ91D镁合金的耐磨损性,其中,SiC质量分数从10%增加到30%过程中磨损体积损失逐渐减少,SiC质量分数在20%~30%时熔覆层具有最好的耐磨性。     

The microstructure, mechanical and friction properties of protective diamond like carbon films on magnesium alloy

Protective hard coatings deposited on magnesium alloys are believed to be effective for overcoming their poor wear properties. In this work, diamond-like carbon (DLC) films as hard protective films were deposited on AZ91 magnesium alloy by arc ion plating under negative pulse bias voltages ranging from 0 to −200 V. The microstructure, composition and mechanical properties of the DLC films were analyzed by scanning electron microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy and nanoindentation. The tribological behavior of uncoated and coated AZ91 magnesium alloy was investigated using a ball-on-disk tribotester. The results show that the negative pulse bias voltage used for film deposition has a significant effect on the sp³ carbon content and mechanical properties of the deposited DLC films. A maximum sp³ content of 33.3% was obtained at −100 V, resulting in a high hardness of 28.6 GPa and elastic modulus of 300.0 GPa. The DLC films showed very good adhesion to the AZ91 magnesium alloy with no observable cracks and delamination even during friction testing. Compared with the uncoated AZ91 magnesium alloy, the magnesium alloy coated with DLC films exhibits a low friction coefficient and a narrow, shallow wear track. The wear resistance and surface hardness of AZ91 magnesium alloy can be significantly improved by coating a layer of DLC protective film due to its high hardness and low friction coefficient.     

Effect of cw-CO2 laser surface treatment on structure and properties of AZ91 magnesium alloy

In the study, samples of AZ91 magnesium alloy were subjected to a surface remelting treatment by means of a continuous wave (cw) CO₂ laser. The scope of the investigation included both macro- and microstructural examination, hardness measurements, and wear resistance tests. The investigation has shown that remelting treatment leads to a strong refinement of structure in the surface layer and a more even distribution of phases. Fine α-phase dendrites have been observed to dominate in the remelting zone. The dendritic arm spacing in the laser treated surface was in the range of 1–2.5 μm. The structural changes triggered by remelting have contributed to an increase in the hardness and the wear resistance of AZ91 alloy. The microhardness of the remelted zone has increased to 71–93 HV_0.05 for single-strip remelting and to 84–107 HV_0.05 for multi-strip remelting in comparison with about ~60 HV_0.05 for untreated alloy. The friction coefficient has decreased from 0.375 for material w/o treatment to 0.311 for remelted material. SEM investigations of samples after tribological tests have revealed the presence of parallel grooves proving the occurrence of microploughing and micro cutting of the material during the tribological testing. The results of the conducted investigation have indicated a beneficial influence of the cw-CO₂ laser remelting treatment on the structure and properties of AZ91 alloy.     

Improving wear resistance of pure copper by laser surface modification

With the aim of improving surface strength on copper with the electrical conductivity of the integral bulk retained, laser surface modification on copper was carried out using powder preplacement. The microstructures, hardness, wear resistance and electrical conductivity of the sample was investigated. It was shown that the modified layer of sample had crack-free, fine and homogeneous microstructures. Compared with pure copper, the average hardness of the sample was enhanced by a factor of six (about HV_0.1650), and the wear mass loss was reduced by 4/5, but the electrical conductivity of the integral bulk was only slightly decreased. The improvement of hardness and wear resistance could be attributed to the precipitation hardening of boride and carbide, grain refinement and solid solution strengthening in the layer.     

Dry sliding tribological behavior of AZ31 magnesium alloy irradiated by high-intensity pulsed ion beam

The dry sliding tribological behavior of AZ31 magnesium alloy irradiated by high-intensity pulsed ion beam (HIPIB) at energy density of 3.4 J/cm² with 10 shots is investigated by dry sliding wear tests in order to explore the effect of HIPIB irradiation on tribological property of magnesium alloy. Surface morphologies, composition and structure of the irradiated AZ31 magnesium alloys are examined by electron probe microanalysis (EPMA) and X-ray diffraction (XRD). The results indicated that HIPIB irradiation led to the increase in surface microhardness and the reduction in friction coefficient and wear rate. Wear rate for both the original and the irradiated samples increased with increasing sliding load from 0.1 to 0.5 N. The transition from severe metallic wear to mild oxidative wear induced by HIPIB irradiation was observed by a combined analysis in surface morphology and chemical composition of wear tracks, mechanically mixed materials and wear debris, which is mainly attributed to the significant increase in microhardness resulting from grain refinement on the irradiated surface. In addition, defects induced by HIPIB irradiation promoted the diffusion of oxygen during sliding wear and therefore led to the formation of compact mixed materials and protective films on the wear tracks surface, which also contributes to the transition in wear mechanism of AZ31 magnesium alloy induced by HIPIB irradiation.     

Laser (a pulsed Nd:YAG) cladding of AZ91D magnesium alloy with Al and Al2O3 powders

The laser surface cladding of an AZ91D magnesium alloy with Al and Al₂O₃ powders was investigated using a pulsed Nd:YAG laser. The optimum ratio of Al to Al₂O₃ and the suitable range of laser processing parameters were identified. The resulting microstructure in the modified surface layer was examined and the wear resistance property was evaluated. The results show that the wear resistance of the laser treated samples was much superior to that of the untreated samples.     

Effect of pulsed laser parameters on in-situ TiC synthesis in laser surface treatment

Commercial titanium sheets pre-coated with 300-μm thick graphite layer were treated by employing a pulsed Nd:YAG laser in order to enhance surface properties such as wear and erosion resistance. Laser in-situ alloying method produced a composite layer by melting the titanium substrate and dissolution of graphite in the melt pool. Correlations between pulsed laser parameters, microstructure and microhardness of the synthesized composite coatings were investigated. Effects of pulse duration and overlapping factor on the microstructure and hardness of the alloyed layer were deduced from Vickers micro-indentation tests, XRD, SEM and metallographic analyses of cross sections of the generated layer. Results show that the composite cladding layer was constituted with TiC intermetallic phase between the titanium matrix in particle and dendrite forms. The dendritic morphology of composite layer was changed to cellular grain structure by increasing laser pulse duration and irradiated energy. High values of the measured hardness indicate that deposited titanium carbide increases in the conditions with more pulse duration and low process speed. This occurs due to more dissolution of carbon into liquid Ti by heat input increasing and positive influence of the Marangoni flow in the melted zone.     

Composition design and laser cladding of Ni-Zr-Al alloy coating on the magnesium surface

The cluster line criterion was used for optimized design of a Ni-Zr-Al alloy used as coating on the AZ91HP magnesium alloy by laser cladding. Results show that the coating mainly consists of an amorphous, two ternary intermetallic phases with Ni₁₀Zr₇ and Ni₂₁Zr₈ type structures resulting in high hardness, good wear resistance and corrosion resistance. The interface between the clad layer and the substrate has good metallurgical bond.     

Electrical discharge machining of titanium alloy (Ti-6Al-4V)

In this study, the electrical discharge machining (EDM) of titanium alloy (Ti-6Al-4V) with different electrode materials namely, graphite, electrolytic copper and aluminium and process parameters such as, pulse current and pulse duration were performed to explore the influence of EDM parameters on various aspects of the surface integrity of Ti6Al4V. Scanning electron microscopy (SEM), X-ray diffraction (XRD), energy dispersive spectrograph (EDS) and hardness analysis were performed. The experimental results reveal that the value of material removal rate, surface roughness, electrode wear and average white layer thickness are tendency of increase with increasing current density and pulse duration. However, extremely long-pulse durations such as 200 μs led to decrease MRR and surface roughness. Furthermore, the surface hardness is increasing due to the Ti₂₄C₁₅ carbides formed on the surface and obvious cracks are always evident in re-solidified layer when machining copper electrode. The surface crack densities and critical crack lines were determined for the tested material. The graphite electrode is beneficial on material removal rate, electrode wear and surface crack density but relatively poorer surface finish.     

Bi，Sb及稀土元素对AZ91镁合金高温性能影响机理研究

利用大角重位点阵概念建立了AZ91镁合金基体(α相)和镁［0001］对称倾斜晶界原子结构模型,应用实空间的连分数方法计算了体系的结构能,环境敏感镶嵌能以及相互作用能.结果发现,在镁合金基体中,Al和稀土形成团簇时比较稳定,Al,Bi或Sb与稀土形成团簇时不稳定.Bi或Sb和稀土元素同时存在于AZ91镁合金中时,一方面Bi或Sb将可与RE结合形成RE₂Bi(RE₂Sb)或RE-Bi(RE-Sb)化合物弥散分布于晶界,另一方面镁合金基体中会形成Al_{11关键词： 电子理论 晶界偏聚 合金元素 高温性能}     

Physicomechanical properties of the surface of a zirconium alloy modified by a pulsed ion beam

The physicomechanical properties of the surface of the Zr-1% Nb zirconium alloy modified by a pulsed carbon ion beam with a pulse duration of 80 ns, an energy of 200 keV, and a current density of 120 A/cm² are studied at four regimes having different numbers of pulses. Irradiation by a carbon ion beam results in hardening of the surface layer to a depth of 2 μm, grain refinement to 0.15–0.8 μm, zirconium carbide formation, and a decrease in the hydrogen permeability of the zirconium alloy.     

Microstructure performance and formation mechanism of laser alloying rare earth oxides modified nanocrystalline layer on TA7

Nanoscale particles (NP) were observed in a Ni60–Ag–Si₃N₄–Y₂O₃ laser alloying (LA) layer on a TA7 titanium alloy, NP usually locate on the grain boundaries, which are able to block the motion of dislocation in a certain extent. Such layer mainly consisted of γ-Ni, TiN, γ-(Fe, Ni), TiAg and lots of amorphous phases. The wear resistance of such layer with laser scanning speed 3 mm/s was better than that of a LA layer with 6 mm/s, which was mainly ascribed to an uniform microstructure and less defect of layer. The high laser scanning speed made the existing time of laser molten pool be shorter than before, favoring the formation of a fine microstructure. However, the defects, such as pores were produced in LA layer (higher scanning speed), decreasing the wear resistance.     

Microstructure and properties of Ni-Co/nano-Al2O3 composite coatings by pulse reversal current electrodeposition

Ni-Co/nano-Al₂O₃ (Ni-Co/Al₂O₃) composite coatings were prepared under pulse reversal current (PRC) and direct current (dc) methods respectively. The microstructure of coatings was characterized by means of XRD, SEM and TEM. Both the Ni-Co alloy and composite coatings exhibit single phase of Ni matrix with face-centered cubic (fcc) crystal structure, and the crystal orientation of the Ni-Co/Al₂O₃ composite coating was transformed from crystal face (2 0 0) to (1 1 1) compared with alloy coatings. The hardness, anti-wear property and macro-residual stress were also investigated. The results showed that the microstructure and performance of the coatings were greatly affected by Al₂O₃ content and the electrodeposition methods. With the increasing of Al₂O₃ content, the hardness and wear resistance of the composite coatings enhanced. The PRC composite coatings exhibited compact surface, high hardness, better wear resistance and lower macro-residual stress compared with that of the dc composite coatings.     

Surface modification of Al-20Si alloy by high current pulsed electron beam

Hypereutectic Al-20Si (Si 20 wt.%, Al balance)alloy surface was treated with high current pulsed electron beam (HCPEB) under different pulse numbers. The results indicate that HCPEB irradiation induces the formation of metastable structures on the treated surface. The coarse primary Si particle melts, producing a “halo” microstructure with primary Si as the center on the melted surface. A supersaturated solid solution of Al is formed in the melted layer caused by Si atoms dissolving into the Al matrix. Cross-section structure analysis shows that a 4 μm remelted layer is formed underneath the top surface of the HCEPB-treated sample. Compared with the matrix, the Al and Si elements in the remelted layer are distributed uniformly. In addition, the grains of the Al-20Si alloy surface are refined after HCPEB treatment, as shown by TEM observation. Nano-silicon particles are dispersed on the surface of remelted layer. Polygonal subgrains, approximately 50-100 nm in size, are formed in the Al matrix. The hardness test results show that the microhardness of the α(Al) and eutectic structure is increased with increasing pulse number. The hardness of the “halo” microstructure presents a gradient change after 15 pulse treatment due to the diffusion of Si atoms. Furthermore, hardness tests of the cross-section at different depths show that the microhardness of the remelted layer is higher than that of the matrix. Therefore, HCPEB technology is a good surface modification method for enhancing the surface hardness of hypereutectic Al-20Si alloy.     

Development and characterization of laser surface cladding (Ti,W)C reinforced Ni–30Cu alloy composite coating on copper

To improve the wear resistance of copper components, laser surface cladding (LSC) was applied to deposit (Ti,W)C reinforced Ni–30Cu alloy composite coating on copper using a cladding interlayer of Ni–30Cu alloy by Nd:YAG laser. The microstructure and phases of the composite coating were investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray energy dispersive microanalysis (EDX). Microhardness tester and pin-on-disc wear tester were employed to evaluate the hardness and dry-sliding wear resistance. The results show that crack-free composite coating with metallurgical bonding to the copper substrate is obtained. Phases identified in the (Ti,W)C-reinforced Ni–30Cu alloy composite layer are composed of TiWC₂ reinforcements and (Ni,Cu) solid solution. TiWC₂ reinforcements are distributed uniformly in the (Ni,Cu) solid solution matrix with dendritic morphology in the upper region and with particles in the mid-lower region. The microhardness and wear properties of the composite coating are improved significantly in comparison to the as-received copper substrate due to the addition of 50 wt% (Ti,W)C multicarbides.     

Plasma electrolytic oxidation coating on AZ91 magnesium alloy modified by neodymium and its corrosion resistance

Ceramic coatings on the surfaces of Mg-9Al-1Zn (AZ91) magnesium alloy and Mg-9Al-1Zn-1Nd magnesium alloy (AZ91 magnesium alloy modified by neodymium, named as AZ91Nd in this paper) are synthesized in aluminate electrolyte by plasma electrolytic oxidation (PEO) process, respectively. X-ray diffraction and X-ray photoelectron spectroscopy analyses show the PEO coating on the Mg-9Al-1Zn-1Nd alloy comprises not only MgO and Al₂O₃, which are found in the coating on the AZ91 alloy, but also a trace amount of Nd₂O₃. Microstructure observations indicate the addition of Nd can decrease the sizes of β phases and form Al₂Nd intermetallics in the AZ91 alloy. The fine β phases can effectively restrain the formation of unclosed-holes and greatly decrease the sizes of pores in the coating during the PEO process. In addition, the Al₂Nd intermetallics can be completely covered due to the lateral growth of the PEO coatings formed on the α and β phases. As a result, the coating on the AZ91Nd alloy possesses a dense microstructure compared with that on the AZ91 alloy. The following corrosion tests indicate the corrosion resistance of the PEO coating on the AZ91Nd alloy is evidently higher than that of the PEO coating on the AZ91 alloy.     

Numerical and experimental studies of molten pool formation during an interaction of a pulse laser (Nd:YAG) with a magnesium alloy

A pulse laser (Nd:YAG) interaction with an AZ91 magnesium alloy has been experimentally and numerically studied. A two-dimensional (2D) axisymmetric model of a molten pool created by a laser heat source has been developed. The elaborated model solves the coupled equations of a laminar fluid flow and heat transfer to demonstrate the flow behavior in the pool. This model takes into account the coupled effects of buoyancy and Marangoni forces, the thermophysic variation properties with temperature, and the radiation and convection heat losses. Concerning numerical results, the molten temperature distribution, velocity field and molten shape were discussed. It was noted that the Marangoni flow significantly alters the characteristics of the thawing and solidifying processes, and makes the molten pool wider and shallower. On the other hand, the experimental results showed that the material thermal properties have significant effects on the transport phenomena which takes place in the molten pool, and consequently on the formation as well as the shape of the pool. Finally, a comparison between the numerical and experimental results exhibited a good agreement.     

Electrodeposition of Al-Mn alloy on AZ31B magnesium alloy in molten salts

The Al-Mn alloy coatings were electrodeposited on AZ31B Mg alloy in AlCl₃-NaCl-KCl-MnCl₂ molten salts at 170 °C aiming to improve the corrosion resistance. However, in order to prevent AZ31B Mg alloy from corrosion during electrodeposition in molten salts and to ensure excellent adhesion of coatings to the substrate, AZ31B Mg alloy should be pre-plated with a thin zinc layer as intermediate layer. Then the microstructure, composition and phase constituents of the coatings were investigated by scanning electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDX), and X-ray diffraction (XRD). It was indicated that, by adjusting the MnCl₂ content in the molten salts from 0.5 wt% to 2 wt%, the Mn content in the alloy coating was increased and the phase constituents were changed from f.c.c Al-Mn solid solution to amorphous phase. The corrosion resistance of the coatings was evaluated by potentiodynamic polarization measurements in 3.5% NaCl solution. It was confirmed that the Al-Mn alloy coatings exhibited good corrosion resistance with a chear passive region and significantly reduced corrosion current density at anodic potentiodynamic polarization. The corrosion resistance of the alloy coatings was also related with the microstructure and Mn content of the coatings.     

Electroless Ni-P/Ni-B duplex coatings for improving the hardness and the corrosion resistance of AZ91D magnesium alloy

The Ni-P/Ni-B duplex coatings were deposited on AZ91D magnesium alloy by electroless plating process and their structure, morphology, microhardness and corrosion resistance were evaluated. The duplex coatings were prepared using dual baths (acidic hypophosphite- and alkaline borohydride-reduced electroless nickel baths) with Ni-P as the inner layer. The coatings were amorphous in as-plated condition and crystallized and produced nickel borides upon heat-treatment. SEM observations showed that the duplex interface on the magnesium alloy was uniform and the compatibility between the layers was good. The Ni-P/Ni-B coatings microhardness and corrosion resistance of having Ni-B coating as the outer layer was higher than Ni-P coatings. The Ni-P/Ni-B duplex coatings on AZ91D magnesium alloy with high hardness and good corrosion resistance properties would expand their scope of applications.     

Correlation between the surface chemistry and the atmospheric corrosion of AZ31, AZ80 and AZ91D magnesium alloys

X-ray photoelectron spectroscopy (XPS) was used in order to investigate the correlation between the surface chemistry and the atmospheric corrosion of AZ31, AZ80 and AZ91D magnesium alloys exposed to 98% relative humidity at 50 °C. Commercially pure magnesium, used as the reference material, revealed MgO, Mg(OH)₂ and tracers of magnesium carbonate in the air-formed film. For the AZ80 and AZ91D alloys, the amount of magnesium carbonate formed on the surface reached similar values to those of MgO and Mg(OH)₂. A linear relation between the amount of magnesium carbonate formed on the surface and the subsequent corrosion behaviour in the humid environment was found. The AZ80 alloy revealed the highest amount of magnesium carbonate in the air-formed film and the highest atmospheric corrosion resistance, even higher than the AZ91D alloy, indicating that aluminium distribution in the alloy microstructure influenced the amount of magnesium carbonate formed.