等离子喷涂镍基可磨耗封严涂层抗腐蚀及耐磨性能分析

doi:10.15541/jim20150566

摘要/Abstract

摘要：

采用高效能超音速等离子喷涂沉积Ni-C及NiCrAl-BN可磨耗封严涂层, 对比研究两种涂层的抗冲蚀磨损、耐腐蚀及摩擦磨损性能。结果表明: 两种涂层中的润滑相均匀分布在金属连续相之中, 但与Ni-C涂层相比, NiCrAl-BN涂层中的润滑相尺寸较为细小, 表面硬度较高。当冲蚀角度由30°增加到90°后, 两种涂层冲蚀磨损失重量明显提高。NiCrAl-BN涂层的相对冲蚀速率约为Ni-C涂层的50%, 表明NiCrAl-BN涂层具有较为优良的抗冲蚀性能。Ni-C涂层在稀盐酸中(1vol%)发生了明显的电化学腐蚀, 在石墨片周围容易形成腐蚀产物; 酸液会沿NiCrAl-BN涂层中的孔隙渗入, 从而造成金属的局部腐蚀, 但腐蚀程度明显较Ni-C轻。随着环境温度的升高, 以BN为主的第二相润滑组元的塑性和流动性增强, 使摩擦表面原本较小的、不连续的润滑型保护膜逐渐铺展开来, 形成面积较大且呈连续分布的鳞片状自润滑保护膜。原来在较低温度下润滑膜中存在的裂纹、疏松或剥离等缺陷明显减少, 导致NiCrAl-BN涂层摩擦系数大幅度降低, 从而显示出优异的高温自润滑性能。

关键词: 可磨耗封严涂层, 超音速等离子喷涂, 冲蚀, 腐蚀, 摩擦磨损

Abstract:

High-efficiency supersonic atmospheric plasma spraying was used to fabricate Ni-C and NiCrAl-BN abradable seal coatings. The erosion wear, corrosion resistance and wear resistance of plasma-sprayed coatings were comparatively studied．Experimental results showed that the libricating phases were homogeneously distributed in the as-sprayed coatings while their average size of the coating was much fine compared with Ni-C coating, and the former also showed higher surface hardness than the latter. Meanwhile, it was found that the erosive mass loss increased with the increase of impingement angle from 30° to 90° and the relative erosion rate of NiCrAl-BN coating was only a half of that of Ni-C coating. Due to the formation of corrosion product around the flake graphite, the corrosion resistance of NiCrAl-BN coating was better than Ni-C coating in dilute hydrochloric acid (1vol%). However, the hydrochloric acid could permeate the NiCrAl-BN coating through the pores, which resulted in the localized corrosion of metal phases. In addition, we also observed that the friction coefficient of NiCrAl-BN coating significantly decreased from room temperature to 400℃ owing to the formation of large-scale self-lubricating film that resulted from the improvement of plasticity and fluidity of BN.

Key words: abradable seal coating, supersonic atmospheric plasma spraying, erosion, corrosion, friction and wear

中图分类号:

TM205

于方丽, 白宇, 吴秀英, 王海军, 吴九汇. 等离子喷涂镍基可磨耗封严涂层抗腐蚀及耐磨性能分析[J]. 无机材料学报, 2016, 31(7): 687-693.

YU Fang-Li, BAI Yu, WU Xiu-Ying, Wang Hai-Jun, WU Jiu-Hui. Corrosion Resistance and Anti-wear Property of Nickel Based Abradable Sealing Coating Deposited by Plasma Spraying[J]. Journal of Inorganic Materials, 2016, 31(7): 687-693.

图/表 13

表1 封严涂层体系材料[12]

Table 1 Materials for abradable seal coating[12]

Material	Product mark	Composition/wt%	Density/ (g·cm^-3)
Ni-C	M 307	Ni75-C25	3.2
NiCrAl-BN	M 301	Ni60Cr14Al-BN5.5	4.4

表2 等离子喷涂工艺参数

Table 2 Spray parameters

Parameters	Ni-C	NiCrAl-BN
Current /A	200	320
Voltage /V	90	90
Primary gas, Ar /(m³·h^-1)	2.8	2.8
Carrier gas flow rate /(L·min^-1)	10	10
Carrier gas pressure / MPa	0.8	0.8
Powder feed rate /(g·min^-1)	40	48

表3 冲蚀磨损试验参数

Table 3 Parameters for erosive wear test

Parameters	Value
Distance /mm	100
Pressure /MPa	0.3
Compressed air flow rate /(m³·h^-1)	3
Inner diameter of nozzle / mm	3.6
Length of nozzle /mm	22
Particle size of abrasive particles-Brown alumina	100#

图1 腐蚀浸泡试样示意图

Fig. 1 Schematic of sample for corrosion test

图2 环状试样(左)和圆盘状试样(右)

Fig. 2 Annular (left) and disc (right) samples with deposited abradable sealing coating for wear test

图3 镍-石墨(Ni-C)喷涂原料粉体及涂层剖面结构

Fig. 3 Ni-C feedstock powder and cross-sectional images of Ni-C as-sprayed coating(a) Feedstock powder; (b) Whole image of coating;; (c) Detailed image of coating

图4 镍铬-氮化硼(NiCrAl-BN)喷涂原料粉体及涂层剖面结构

Fig. 4 NiCrAl-BN feedstock powder and cross-sectional images of NiCrAl-BN coating(a) Feedstock powder; (b) Whole image of coating; (c) Detailed image of coating

图5 封严涂层冲蚀磨损曲线

Fig. 5 Mass loss of coating during erosive wear

图6 在90℃、1vol%HCl腐蚀条件下涂层的失重曲线

Fig. 6 Weight loss of coating after corrosion in 1vol% HCl at 90℃

图7 90℃、1vol%HCl腐蚀10 h后的涂层剖面形貌

Fig. 7 Cross-sectional morphology of coating after corrosion in 1vol% HCl at 90℃(a) Ni-C coating; (b) NiCrAl-BN coating

图8 涂层在不同温度下摩擦系数随时间的变化曲线

Fig. 8 Frictional coefficient of coating as a function of time at different temperatures(a) Room temperature; (b) 200℃; (c) 400℃

图9 NiCrAl-BN涂层室温条件下磨损后的表面形貌

Fig. 9 Morphological images of wear track of NiCrAl-BN coating tested at room temperature(a) Whole image; (b) Detailed image

图10 NiCrAl-BN涂层400℃时磨损后的表面形貌

Fig. 10 Morphological images of wear track of NiCrAl-BN coating tested at 400℃(a) Whole image; (b) Detailed image

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