电弧喷涂不锈钢涂层耐磨性的研究

研究了电弧喷涂３Ｃｒ１３和１Ｃｒ１８Ｎｉ９Ｔｉ不锈钢涂层的耐磨性，分析了喷涂工艺参数对３Ｃｒ１３涂层耐磨性的影响及涂层中孔隙的作用，并且深入探讨了涂层的磨损机理。     

基于扰动波的HVAS液滴耦合振动特性分析

高速电弧喷涂过程中熔融金属液滴的振动特性对喷涂涂层性能具有决定性作用,但限于实验技术很难检测液滴的动力学行为,因而利用扰动波理论建立了气流和液滴的耦合振动方程组,并数值求解获得了喷涂气流最不稳定波数,与Bradley的数据曲线进行了比较,二者呈现出较好的吻合性,误差在士2％之间,验证了所建立的HVAS小扰动液滴模型是有效的;根据HVAS液滴耦合振动模型分析了不同喷涂气流及其速度对不同熔融金属的相应HVAS液滴振动特性。结果表明,HVAS过程中用N2具有一定的优势,且增加气流速度有利于提高喷涂涂层的结合强度,从而为HVAS过程中的材料选择与工艺控制提供了基本的理论依据。     

特征等离子喷涂参数对WC涂层结构和性能影响

采用等离子喷涂在不同的特征等离子喷涂参数(简称CPSP)条件下制备WC复合涂层,探讨了CPP对涂层显微结构、物相、力学性能和摩擦学性能的影响;采用扫描电子显微镜(SEM)和X射线衍射仪(XRD)表征了涂层的显微结构,通过球盘式摩擦试验机评价了涂层的摩擦磨损性能.结果表明:CPSP对粉末在熔化过程中热物理行为具有重要影响;随着CPSP降低,涂层显微结构、力学性能和摩擦磨损性能均得到了较大改善;试验证实了通过合理优化参数,等离子喷涂也可以制备出性能与超音速火焰喷涂(HVOF)相近的高质量WC涂层.     

干摩擦条件下3Cr13 涂层的加速磨损机理研究

在MM200摩擦磨损试验机上对高速电弧喷涂3Cr13涂层在干摩擦条件下的加速磨损机理进行了研究.涂层在加速磨损过程中经历了跑合磨损、稳定磨损、剧烈磨损这三个不同的阶段.采用扫描电镜、X射线衍射仪、显微硬度仪和纳米压痕仪对涂层磨损各阶段的截面形貌、残余应力、硬度和纳米力学性能进行了表征.结果表明:在加速磨损寿命3个阶段中,涂层的磨损机制和影响残余应力的主导因素是动态变化的,过分的冷作硬化加剧了涂层的失效,涂层磨损寿命长短关键在于稳定磨损时间的长短.     

油润滑条件下FeBSiNb非晶涂层磨损性能研究

基于机器人自动化高速电弧喷涂技术在45^#钢基体上制备了FeBSiNb非晶涂层.研究了非晶涂层在油润滑条件下磨损时间、线速度和载荷对涂层的磨损行为.采用扫描电镜(SEM)、能谱分析仪(EDAX)和X射线衍射仪(XRD)等仪器对涂层的组织结构进行了表征,利用纳米压痕仪对涂层的微观力学性能进行了分析.结果表明:涂层具有非晶态结构,组织均匀,层状结构紧凑,具有较低的孔隙率(1.4%)和较高的显微硬度(16.42 GPa).随着磨损速度升高,载荷增加,涂层的磨损率也随之增加.FeBSiNb非晶涂层具有良好的耐磨性,同一磨损条件下,其相对耐磨性为3Cr13涂层的6倍.FeBSiNb非晶涂层的磨损机制主要为脆性疲劳剥落.     

Fe基非晶纳米晶电弧喷涂层的摩擦学性能

采用自动化高速电弧喷涂技术在AZ91镁合金基体上制备了FeCrBSiMnNbW非晶纳米晶涂层.研究了涂层材料在干摩擦条件下的摩擦学性能.采用配备有能谱分析仪（EDAX）的扫描电子显微镜（SEM）和X射线衍射仪（XRD）对涂层的微观组织结构进行了表征.采用显微硬度计和纳米压痕仪对涂层的力学性能进行了分析,摩擦磨损试验在UMT-2型摩擦磨损试验机上进行,并采用三维白光干涉表面形貌仪（Phase Shift MicroWAM-3D）测定磨损量.结果表明：涂层组织均匀、结构致密、氧化物含量低,涂层主要由非晶相和纳米晶相组成;涂层具有较高的硬度和弹性模量;在相同的试验条件下,非晶纳米晶合金涂层的相对耐磨性是传统3Cr13涂层的3倍;磨损机制主要为典型的脆性剥落.     

不同载荷下3Cr13不锈钢涂层磨损寿命研究

在T-11摩擦磨损试验机上研究了不同载荷下高速电弧喷涂3Cr13不锈钢涂层的磨损寿命.提出载荷-涂层磨损寿命耦合的关系函数方程.通过对涂层磨损形貌观察,分析了不同载荷对磨损失效机制的影响.结果表明:当载荷较低时,涂层磨损寿命分散程度大,磨损主要失效机制为点蚀和剥落;当载荷较高时,涂层磨损寿命分散程度小,分层是引发涂层磨损失效的关键机制.     

电弧喷涂纳米结构涂层的组织与磨损性能

基于机器人自动化高速电弧喷涂技术在45#钢基体上制备了铁基纳米结构涂层.研究了纳米结构涂层在不同磨损速度?不同载荷下的磨损行为,并利用3Cr13涂层进行对比试验.采用扫描电镜?能谱分析仪,透射电镜和X射线衍射仪等设备对涂层的组织结构进行了表征,利用纳米压痕仪对涂层的力学性能进行了分析.结果表明:涂层的组织主要由非晶相和α(Fe,Cr)相纳米晶组成;平均尺寸为46nm的α(Fe,Cr)相纳米晶均匀分布于非晶基体内.涂层的组织均匀,结构致密,平均孔隙率含量为1.7%.纳米结构涂层具有较高的显微硬度;随着磨损速度升高,载荷增加,纳米结构涂层的磨损量也随之增加.纳米结构涂层具有良好的耐磨性,同一磨损条件下,其相对耐磨性为3Cr13涂层的2.6倍.纳米结构涂层主要磨损机制为脆性断裂机制.     

含WC陶瓷相电弧喷涂层耐磨粒磨损性能的研究

采用电弧喷涂含WC-CoNi金属陶瓷粉末的粉芯丝材,在低碳钢基体上制备铁基复合涂层,采用MLS-225型湿砂橡胶轮磨损试验机评价铁基复合涂层的耐磨粒磨损性能,利用光学显微镜、扫描电子显微镜和X射线衍射仪对涂层的显微组织结构、磨损表面及其相组成进行分析.结果表明:含WC陶瓷相涂层的耐磨粒磨损性能较好,相对Q235钢提高约9倍;当粉芯中WC质量分数低于25%时,随着WC含量增加,涂层的硬度和耐磨性增加;当粉芯中WC质量分数超过25%后,涂层的耐磨性有所下降;电弧喷涂含WC陶瓷相涂层的磨损机制主要为硬质相的脆性剥离和轻微的塑性切削,在磨粒磨损条件下硬度较低的金属基体先磨损,硬度较高的WC和Fe3B硬质相起到阻止石英砂磨损的作用,从而降低了涂层的磨损.     

采用两种喷涂技术制备铁基合金涂层的摩擦磨损特性研究

利用超音速火焰喷涂(HVOF)技术和等离子喷涂(ASP)技术,分别在0Cr13Ni5Mo不锈钢基体上制备了铁基非晶合金涂层和铁基非晶纳米晶涂层,研究了2种涂层在室温下的摩擦磨损特性,并探讨其磨损机理.结果表明,2种热喷涂涂层中以等离子喷涂工艺制备的铁基非晶纳米晶涂层的耐磨性较好,其主要原因是等离子喷涂涂层具有高硬度的同时在涂层中弥散分布着纳米晶颗粒,两者共同增强了涂层的耐磨性能.采用等离子喷涂技术制备的涂层的磨损机制主要为磨粒磨损,而超音速火焰喷涂技术制备的涂层的磨损机理为粘着磨损和疲劳磨损的综合作用,其中以疲劳磨损为主.     

基于复数神经网络的粘弹性材料动态模量拟合方法

固体火箭发动机药柱粘弹性材料除具有弹塑性特性,还具有粘滞性,这一特性使得材料变形具有明显的时间效应,本构关系复杂,进行动态力学分析时,动态模量难以有效拟合．本文提出了一种基于(Levenberg-Marquardt, L-M)算法的复数神经网络拟合粘弹性材料动态模量的方法．通过广义Maxwell模型推导得到材料的动态模量表达式,以此构造未定网络参数为复数的神经网络,从而提供了一种输入、输出样本均为复数的神经网络解决方法．将实数L-M训练算法进行改进,衍生到复数领域,提出复数L-M训练算法．通过粘弹性材料实验,将实验数据时温等效转换,获得复数神经网络的训练及测试样本．通过对神经网络进行训练,实现粘弹性材料动态模量的高精度拟合．数值算例表明,与传统神经网络拟合方法相比,所提方法在训练速度和泛化能力方面都有其优越性．     

A numerical and experimental investigation into residual stress in thermally sprayed coatings

This paper is concerned with an investigation into the thermal spray process and is particularly concerned with the residual stresses that arise when a steel-alloy coating is sprayed onto a copper-alloy substrate. This material combination was used recently to enhance the thermal and mechanical efficiency of the pressure die casting process. A difficulty with the spraying of steel on copper is the attainment of appreciable thickness of the coating due to debonding during the thermal spraying process. Prominent among possible causes of debonding is residual stress, which is the focus of the research presented in the paper. An investigation into the thermal spray process is performed using experimentation, simplified numerical modelling and finite element modelling. The development of residual stress for a range of process parameters, i.e. deposited layer thickness, interval of layer deposition and the number of layers in a coating (i.e. block deposition versus multilayer deposition for a desired coating thickness) is recorded. The results from the three investigation methods agreeably indicate a progressive change in average interfacial residual stress from compressive towards tensile with increase in thickness of deposited layer; and a tensile interfacial stress in a two-layer coating, which increases with increase in interval of deposition between the two layers. On the whole, the observations from the results suggest an increase in potential for coating debonding with increase in both deposited layer thickness and layer deposition interval. The results further suggest higher potential for coating debonding with block deposition compared to multilayer deposition for a desired coating thickness.     

考虑界面应力时纳米涂层纤维增强复合材料的有效力学性能

基于Gurtin-Murdoch表/界面理论和广义自洽方法,获得了考虑界面应力时纳米涂层纤维增强复合材料有效反平面剪切模量的闭合形式解。讨论了涂层的壁厚、力学性能和界面性能对复合材料有效性能的影响。结果显示：在纳米尺度范围内,复合材料的有效反平面剪切模量受纳米涂层的尺寸影响显著。纤维体积分数一定时,涂层壁厚越大,纤维半径越小,有效反平面剪切模量与经典结果偏差越大。纤维刚度和涂层界面性能对复合材料有效模量的影响也取决于涂层刚度,非常软或非常硬的涂层都大大限制了纤维刚度对复合材料有效模量的贡献,过高的涂层刚度屏蔽了纳米复合材料表/界面效应的影响。     

考虑频率依赖性的涂层复合结构固有特性求解

粘弹性阻尼材料的力学特性参数会随着频率的变化而改变,即具有频率依赖性,因而传统的动力学建模及分析方法不能满足实际涂层结构优化设计的需要。在简要介绍粘弹性阻尼材料频率依赖性的基础上,本文提出用特征向量增值法来求解涂层复合结构的固有特性,并详细推导了特征向量增值法的求解原理。由此,提出了特征向量增值法的计算流程,包括计算无阻尼系统的固有特性,用Fox and Kapoor或者Nelson方法计算复特征向量增量;用Rayleigh熵法求解复特征值。最后,以涂敷粘弹性阻尼材料的钛基薄板为例,求解了该复合结构的固有特性,并与经典的模态应变能法进行了比较,证明了所提方法的正确性。     

Nano-Ni粉体对Fe/WC涂层组织和性能的影响

在Fe/WC喷涂材料中添加不同量的Nano-Ni粉体,采用亚音速火焰喷涂技术在Q235基体上制备涂层,利用光学显微镜、扫描电子显微镜、X射线衍射仪等设备进行显微组织、表面形貌观察及物相分析,利用MM-W1磨损试验机和HXD-1000TM型显微硬度仪对涂层的性能进行测试.结果表明:Nano-Ni粉体可以细化涂层组织,提高涂层的致密性,随着Nano-Ni粉体添加量的增大,相应的力学性能均得到提高,在涂层形成过程中Nano-Ni粉体与喷涂材料中的其他成分形成了一些新相,如Fe-Ni固溶体和CeNi3,这些新相为改善涂层组织和提高涂层的力学性能起到积极作用.     

Dynamic stress intensity factor of the weak/micro-discontinuous interface crack of a FGM coating

The concepts and classification are brought forth for the strong-discontinuous interface, the weak-discontinuous interface, the micro-discontinuous interface and the all-continuous interface. The mechanical model is established for the dynamic fracture problem of the weak-discontinuous interface between a FGM coating and a FGM substrate. The Cauchy singular integral equation for the crack is derived by integral transform, and the allocation method is used to get the numerical solution. Analysis of the numerical solution indicates that the weak discontinuity is an important factor affecting the SIFs of the interfacial crack. To reduce the weak discontinuity is beneficial to the decrease of the SIFs. Contrast between the solution of the weak-discontinuous interface and that of the micro-discontinuous one shows that the micro-discontinuity is a kind of connection relation of mechanical property better than the weak discontinuity for the coating–substrate structure. To make the interface be micro-discontinuous is helpful to enhance the capacity of the functionally gradient coating–substrate interface to resist dynamic fracture. The first rank micro-discontinuity is enough to reduce the SIFs notably, however, the higher-rank micro-discontinuous terms, which is equal to or higher than the second rank, have less effect on the SIFs. In addition, the thickness of the coating and the substrate and the applied peel stress are also important factors affecting the dynamic SIFs.     

Static and fatigue behavior of metal cylinders with enhanced surface property

Effects of surface property on the static and fatigue strength of metal cylinders is determined by analysis of the redistribution of stress and energy density. Because the mechanical constraints on the material elements in a surface layer differ so drastically from those in the interior or bulk, changes of mechanical properties in a thin surface layer can significantly alter the global behavior of a metal part. Desirable gain in mechanical strength due to surface treatments such as laser spraying, ion implantation, etc. is now well known. Developed in this work is a method for evaluating the enhancement of the static and fatigue life of metals when their mechanical properties in a thin surface layer of material are improved. An extensive increase in the surface layer thickness does not lead to appreciable changes of mechanical strength.