等离子喷涂层的竞争性失效行为和寿命预测研究
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摘要
钻探机具是钻探工程和地质工程装备中的关键零部件，磨粒磨损、粘着磨损、接触疲劳、腐蚀磨损等常见的表面失效对于钻探机具的服役可靠性、生产安全和工作效率具有不可忽视的影响。因此，采用先进的表面工程技术对钻探机具易损零部件表面进行强化，提高其耐磨耐蚀性能，是避免钻探装备失效并延长其服役寿命的有效途径。超音速等离子喷涂Al_2O_3/40%wt. TiO_2复合陶瓷涂层的致密度、韧性和结合强度较高，具有优异的耐磨性和相对较好的耐蚀性及耐接触疲劳性能，适用于对钻探机具易损件进行表面强化。
本文采用正交优化试验的方法，研究了超音速等离子喷涂Al_2O_3/40%wt. TiO_2复合陶瓷涂层过程中喷涂距离、喷涂电流、喷涂电压和氩气流量等喷涂参数对涂层质量的影响规律，确定了最优喷涂参数，并采用微观分析手段对涂层的微观结构、化学成分和力学性能进行表征和测试。
为了研究复合陶瓷涂层在真实接触状态下的失效机制和寿命演变规律，制造了一台能够通过改变滑差率来实现对“纯滚动”、“滚动/滑动共存”和“纯滑动”等接触状态进行模拟的对辊式接触疲劳/磨损多功能试验机，作为对涂层耐磨性能和接触疲劳性能进行综合评价的力学实验平台。
基于新型接触疲劳/磨损多功能试验机，系统研究了复合陶瓷涂层在不同接触应力水平下的滚动接触疲劳失效行为和寿命演变规律。利用有限元法模拟得到涂层内部及界面处最大剪切应力和正交剪切应力的分布状态，探讨了涂层内部微观结构和剪切应力的分布规律等因素对接触疲劳裂纹萌生与扩展过程的影响，采用经验模态分解法得到了涂层接触疲劳分层失效过程中的典型声发射信号的波形和频谱，建立了涂层接触疲劳寿命的P-N曲线和P-S-N曲线，能够实现对一定接触应力范围内涂层接触疲劳寿命的预测。
系统研究了复合陶瓷涂层在不同滚动/滑动接触状态下的竞争性失效行为和寿命演变规律。发现当存在滑动接触时，涂层的主要失效模式为表面磨损和界面分层，研究了涂层表面、内部及界面处最大剪切应力的分布规律，探讨了表面滑动磨损及其引发的表面微观脆性断裂和涂层减薄进程对界面分层失效的影响机制，采用经验模态分解法分离出滚动/滑动共存状态下涂层表面磨损失效过程中典型的声发射信号的波形和频谱，发现涂层的竞争性寿命服从Weibull分布，且滑差率越高时寿命越分散，建立了涂层竞争性寿命P-N曲线。
Drilling implement are the key parts in the equipment of drilling engineering and geotechnicalengineering. The common surface failure such as abrasive wear, adhesive wear, contact fatigue,and corrosion wear greatly affects the service reliability, production safety and workingefficiency of drilling implement. Thus, in order to improve the wear resistance and corrosionresistance, avoid failure as well as prolong the service life of drilling equipment, advancedsurface engineering technologies are often used to strengthen the surfaces of damageable parts ofdrilling implement. Supersonic plasma spraying Al_2O_3/40%wt. TiO_2composite ceramic coatingswith high density, toughness and bonding strength, possess excellent wear resistance, relativelygood corrosion resistance as well as resistance to contact fatigue properties, which is suitable forsurface strengthening of damageable parts of drilling implement.
This dissertation used the orthogonal test to investigate the effects of spraying parameters suchas spraying distance, spraying current, spraying voltage and argon flow rate on the coatingquality to determine the optimal spraying parameters. Various means of microscopic analysiswere used to characterize the microstructure, chemical composition and mechanical properties ofthe composite ceramic coatings.
In order to study the failure mechanism and life evolution laws of the composite ceramiccoatings under the real contact conditions, a contact fatigue/wear multi-function testing machinewith double roller was made. It can achieve the simulation of "rolling","rolling/slidingcoexistence" and "pure sliding" contact conditions by adjusting the slip ratio, and can be used asa mechanical experimental platform to evaluate the wear resistance and contact fatigueperformance of coatings.
Based on the new type contact fatigue/wear multifunctional testing machine, the failurebehavior and life evolution laws of the composite ceramic coating were investigated underdifferent contact stresses. The finite element method was used to simulate the distribution of themaximum shear stress and orthogonal shear stress within the coating as well as in the interfacebetween the coating and substrate. The effects of coating microstructure and shear stressdistribution on the initiation and propagation process of contact fatigue cracks were alsodiscussed. Empirical mode decomposition method was used to obtain the waveform andspectrum of typical acoustic emission signals during the coating delamination failure process ofcontact fatigue. The P-N and P-S-N curves of contact fatigue life were established. Theseanalyses can realize the contact fatigue life prediction of coatings under a certain contact stressrange.
The competing failure behavior and life evolution laws of the composite ceramic coating were researched under different rolling/sliding contact conditions. It was found that when the slidingcontact existed, the main failure modes of coatings are surface wear and interface delamination.The distributions of the maximum shear stress on the coating surface, within the coating as wellas in the interface between the coating and substrate were also investigated. The effectmechanisms of surface sliding wear, brittle fracture and thinning process on the interfacedelamination failure were discussed. Empirical mode decomposition method was used toseparate the waveform and spectrum of typical acoustic emission signals during the surface wearfailure process under the rolling/sliding coexistence condition. It was found that the competinglife of the coating obeys the Weibull distribution, and the life is more dispersed at higher slipratio. The competing life P-N curve of the coating was finally established.
本文采用正交优化试验的方法，研究了超音速等离子喷涂Al_2O_3/40%wt. TiO_2复合陶瓷涂层过程中喷涂距离、喷涂电流、喷涂电压和氩气流量等喷涂参数对涂层质量的影响规律，确定了最优喷涂参数，并采用微观分析手段对涂层的微观结构、化学成分和力学性能进行表征和测试。
为了研究复合陶瓷涂层在真实接触状态下的失效机制和寿命演变规律，制造了一台能够通过改变滑差率来实现对“纯滚动”、“滚动/滑动共存”和“纯滑动”等接触状态进行模拟的对辊式接触疲劳/磨损多功能试验机，作为对涂层耐磨性能和接触疲劳性能进行综合评价的力学实验平台。
基于新型接触疲劳/磨损多功能试验机，系统研究了复合陶瓷涂层在不同接触应力水平下的滚动接触疲劳失效行为和寿命演变规律。利用有限元法模拟得到涂层内部及界面处最大剪切应力和正交剪切应力的分布状态，探讨了涂层内部微观结构和剪切应力的分布规律等因素对接触疲劳裂纹萌生与扩展过程的影响，采用经验模态分解法得到了涂层接触疲劳分层失效过程中的典型声发射信号的波形和频谱，建立了涂层接触疲劳寿命的P-N曲线和P-S-N曲线，能够实现对一定接触应力范围内涂层接触疲劳寿命的预测。
系统研究了复合陶瓷涂层在不同滚动/滑动接触状态下的竞争性失效行为和寿命演变规律。发现当存在滑动接触时，涂层的主要失效模式为表面磨损和界面分层，研究了涂层表面、内部及界面处最大剪切应力的分布规律，探讨了表面滑动磨损及其引发的表面微观脆性断裂和涂层减薄进程对界面分层失效的影响机制，采用经验模态分解法分离出滚动/滑动共存状态下涂层表面磨损失效过程中典型的声发射信号的波形和频谱，发现涂层的竞争性寿命服从Weibull分布，且滑差率越高时寿命越分散，建立了涂层竞争性寿命P-N曲线。
Drilling implement are the key parts in the equipment of drilling engineering and geotechnicalengineering. The common surface failure such as abrasive wear, adhesive wear, contact fatigue,and corrosion wear greatly affects the service reliability, production safety and workingefficiency of drilling implement. Thus, in order to improve the wear resistance and corrosionresistance, avoid failure as well as prolong the service life of drilling equipment, advancedsurface engineering technologies are often used to strengthen the surfaces of damageable parts ofdrilling implement. Supersonic plasma spraying Al_2O_3/40%wt. TiO_2composite ceramic coatingswith high density, toughness and bonding strength, possess excellent wear resistance, relativelygood corrosion resistance as well as resistance to contact fatigue properties, which is suitable forsurface strengthening of damageable parts of drilling implement.
This dissertation used the orthogonal test to investigate the effects of spraying parameters suchas spraying distance, spraying current, spraying voltage and argon flow rate on the coatingquality to determine the optimal spraying parameters. Various means of microscopic analysiswere used to characterize the microstructure, chemical composition and mechanical properties ofthe composite ceramic coatings.
In order to study the failure mechanism and life evolution laws of the composite ceramiccoatings under the real contact conditions, a contact fatigue/wear multi-function testing machinewith double roller was made. It can achieve the simulation of "rolling","rolling/slidingcoexistence" and "pure sliding" contact conditions by adjusting the slip ratio, and can be used asa mechanical experimental platform to evaluate the wear resistance and contact fatigueperformance of coatings.
Based on the new type contact fatigue/wear multifunctional testing machine, the failurebehavior and life evolution laws of the composite ceramic coating were investigated underdifferent contact stresses. The finite element method was used to simulate the distribution of themaximum shear stress and orthogonal shear stress within the coating as well as in the interfacebetween the coating and substrate. The effects of coating microstructure and shear stressdistribution on the initiation and propagation process of contact fatigue cracks were alsodiscussed. Empirical mode decomposition method was used to obtain the waveform andspectrum of typical acoustic emission signals during the coating delamination failure process ofcontact fatigue. The P-N and P-S-N curves of contact fatigue life were established. Theseanalyses can realize the contact fatigue life prediction of coatings under a certain contact stressrange.
The competing failure behavior and life evolution laws of the composite ceramic coating were researched under different rolling/sliding contact conditions. It was found that when the slidingcontact existed, the main failure modes of coatings are surface wear and interface delamination.The distributions of the maximum shear stress on the coating surface, within the coating as wellas in the interface between the coating and substrate were also investigated. The effectmechanisms of surface sliding wear, brittle fracture and thinning process on the interfacedelamination failure were discussed. Empirical mode decomposition method was used toseparate the waveform and spectrum of typical acoustic emission signals during the surface wearfailure process under the rolling/sliding coexistence condition. It was found that the competinglife of the coating obeys the Weibull distribution, and the life is more dispersed at higher slipratio. The competing life P-N curve of the coating was finally established.
引文
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