等离子喷涂典型耐磨涂层材料体系与性能现状研究

Study on System and Properties of Typical Wear-resisting Coating Materials by Plasma Spraying

等离子喷涂作为重要的热喷涂技术之一,在零件表面强化处理与再制造损伤修复领域具有广泛的应用。由于不同机械零部件工作环境(温度、转速、腐蚀环境、润滑状况等)、基体材质及运动形式等因素存在较大的差异,因而通常需根据其具体服役工况选择最优的表面强化涂层,以满足零件表面摩擦学性能需求,提升机械装备的综合服役性能。基于此,对国内外采用等离子喷涂技术所制备的典型耐磨涂层的材料体系及涂层性能进行了详细地综述,系统介绍了组织成分、物相结构、力学性能、服役工况等因素对典型涂层(包括金属基涂层、陶瓷基涂层及多相复合涂层等)摩擦学性能的影响机理。结果表明,涂层的摩擦学性能受到涂层自身特性相关的内因(包括孔隙率、力学性能、组织成分等)和服役工况相关的外因(包括载荷、频率、润滑状态、工作介质等)的影响;典型金属基耐磨涂层包括Fe基、Ni基和Mo基涂层等,通过表面处理、后处理和工艺优化等手段,可显著改善涂层的摩擦学性能;采取不同的喷涂方式因颗粒熔化程度差异,使陶瓷基涂层产生不同的磨损程度;针对纳米、微米结构的陶瓷基涂层进行对比分析,发现纳米涂层通过吸收应力而降低磨损;复合涂层通过添加润滑相能够降低其摩擦因数、减轻涂层磨损,其中相较于单一润滑相,多组润滑相能通过发挥协同润滑效果,使涂层在不同温度区间下保持良好的耐磨性。最后,对等离子喷涂涂层耐磨性能的提升和优化方向进行了展望。

As one of the important thermal spraying technologies,plasma spraying has been widely used in the field of surface strengthening treatment and remanufacturing damage repair.Due to many differences in mechanical parts work environment(temperature,speed,corrosion environment,lubrication conditions,etc.),substrate materials,movement forms and other factors,it is usually necessary to choose the optimal surface enhancement coating according to their specific service condition to satisfy the demands of the parts surface tribology performance and promote the comprehensive service of machinery and equipment performance.Based on this,the paper gives a detailed overview of the material system and coating performance of typical wear-resistant coatings prepared by plasma spraying technology at home and abroad,and systematically introduces the influence mechanism of such factors as structure composition,phase structure,mechanical properties,and service conditions on the tribological properties of typical coatings(metal-based coatings,ceramic-based coatings and multiphase composite coatings,etc.).And the results showed that the tribological properties of the coating were affected by the internal factors related to the characteristics of the coating itself(porosity,mechanical properties,tissue composition,etc.)and external factors related to the service conditions(including load,frequency,lubrication state,working medium,etc.).The tribological properties of some typical metal-based wear resistant coatings including Fe-based,Ni-based and Mo-based coatings can be significantly improved through surface treatment,post-treatment and process optimization.The wear degree of ceramic coating is different due to the difference of particle melting degree in different spraying methods.It is found that the nano-coating can reduce wear by absorbing stress.The composite coating can reduce its friction coefficient and reduce coating wear by adding lubricating phase.Compared with a single lubricating phase,multiple lubrication groups can exert synergistic lubrication effect to maintain good wear resistance of the coating at different temperature ranges.Finally,the improvement and optimization direction of wear resistance of plasma spraying coating are prospected.