超声表面滚压加工改善40Cr钢综合性能研究
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摘要
本文提出一种超声表面滚压加工(USRP)技术,用以提高材料表面的综合性能。试验设备主要由新改进的数字超声波电源(配有更为精确、稳定的频率跟踪及恒幅控制系统)和USRP处理执行机构组成,其中,加工工作头被创新性地设计为可滚动的球体,从而大幅提高其使用寿命,使USRP处理技术成为真正可应用于实际生产的表面改性新方法。
以轴类用40Cr钢供应态及调质态试样为例,采用透射电镜(TEM)、扫描电镜(SEM)、X-射线衍射分析(XRD)、显微硬度及表面粗糙度测量等分析手段,研究了USRP表面组织结构及各加工参数对于其机械性能的影响规律;通过热稳定性、耐腐蚀性及耐摩擦磨损性能对比试验,分析该技术对于试样使用性能的影响。
实验观察和研究表明:USRP试样表面组织具有梯度分布特征,表面强化及晶粒细化是塑性变形逐渐累积的结果;对于调质态试样,组织中析出的碳化物和弥散分布的合金碳化物在提高材料强度的同时,对位错起到一定的钉扎作用。USRP处理技术可以实现试样表面纳米化,表层晶粒为3~7nm,试样表面形成近百微米的纳米晶层;通过衍射花样分析,初步推测试样中渗碳体相在距表层一定深度内有溶解的现象;表层强烈的微应变通过位错移动、晶界形成等方式得到降低,表层并非微应变最大处。
USRP处理技术中,加工参数对于表面硬化程度、表面粗糙度及表面残余应力均有不同程度的影响;适当的USRP加工能够降低甚至消除前序加工所产生的表面缺陷,但反复的塑性变形也会破坏表面质量,当处理能量大于材料的抗拉强度时,材料表面会产生微观裂纹。
性能对比试验表明:USRP处理可以使40Cr试样的击穿电位和腐蚀电位有不同程度的正移,说明该方法能够提高材料的耐腐蚀性能,且加工参数越大,改善程度越高;USRP试样经400℃保温2h后,表面晶粒有不同程度的长大,且表面微观应变值大幅降低;在不同摩擦条件下,试样表面的磨损机理有所不同,但总体而言,与磨光试样相比,USRP处理可以提高材料表面耐磨性,尤其是在润滑摩擦条件下,提高幅度显著。
Ultrasonic surface rolling processing (USRP) is put forward, in order to improvethe general properties of surfaces. Testing device includes the improved digitalultrasonic power supply (with more accuracy and stable frequency tracing andamplitude controlling systems) and USRP operator, in which, the processing tip isdesigned as a rolling ball, so that the service life can be greatly prolonged, whichmakes USRP more practical and economical.
Take as-supplied, quenched and tempered 40Cr steel as testing material. Analysismethods, including TEM, SEM, XRD, measurements of micro-hardness and surfaceroughness and so on, are used to discuss the micro structure and influence ofprocessing parameters on mechanical properties of USRP surfaces. Contrast tests ofthermal stability, corrosion and wear resistance are carried out to investigate theservice performance of USRP specimens.
Micro-structure observation and test results show that: USRP surface is of gradeddistribution; surface enhancement and grain refinement are the results of plasticdeformation accumulation. As for the quenched and tempered 40Cr specimen, theprecipitated and dispersion-distributed carbide strengthens the surfaces and anchorsthe dislocations. Nanocrystallization can be realized by USRP, with grain size of 3~7nm at the top surface and the nano-structured layer is about 100 micrometers thick.Diffraction patterns indicate that: solution of cementite takes place in a certain rangefrom top surface. Micro strain decreases by dislocation movements and grainboundary formation, so micro strain is not the biggest at the top surface.
USRP parameters have influence on surface hardening, surface roughness andresidual stress to some degree. Appropriate USRP treatment can reduce and eveneliminate the surface defects. However, repeated plastic deformation may damage thesurface, and micro-crack can be induced when processing energy exceeds the tensilestrength.
Contrast tests show that: USRP can make the breakdown potential and corrosionpotential of 40Cr specimens move positively, which indicates the improvement ofcorrosion resistance, and the bigger the parameters are, the better the corrosion
resistance will be. After annealing 2h at 400℃, surface grains grow up to some degree,and the surface micro strain decreases. Under different friction conditions, mechanismof wear surfaces varies. Generally speaking, USRP improves the wear resistance ofsurfaces, especially under lubricating, the increase is obvious.
以轴类用40Cr钢供应态及调质态试样为例,采用透射电镜(TEM)、扫描电镜(SEM)、X-射线衍射分析(XRD)、显微硬度及表面粗糙度测量等分析手段,研究了USRP表面组织结构及各加工参数对于其机械性能的影响规律;通过热稳定性、耐腐蚀性及耐摩擦磨损性能对比试验,分析该技术对于试样使用性能的影响。
实验观察和研究表明:USRP试样表面组织具有梯度分布特征,表面强化及晶粒细化是塑性变形逐渐累积的结果;对于调质态试样,组织中析出的碳化物和弥散分布的合金碳化物在提高材料强度的同时,对位错起到一定的钉扎作用。USRP处理技术可以实现试样表面纳米化,表层晶粒为3~7nm,试样表面形成近百微米的纳米晶层;通过衍射花样分析,初步推测试样中渗碳体相在距表层一定深度内有溶解的现象;表层强烈的微应变通过位错移动、晶界形成等方式得到降低,表层并非微应变最大处。
USRP处理技术中,加工参数对于表面硬化程度、表面粗糙度及表面残余应力均有不同程度的影响;适当的USRP加工能够降低甚至消除前序加工所产生的表面缺陷,但反复的塑性变形也会破坏表面质量,当处理能量大于材料的抗拉强度时,材料表面会产生微观裂纹。
性能对比试验表明:USRP处理可以使40Cr试样的击穿电位和腐蚀电位有不同程度的正移,说明该方法能够提高材料的耐腐蚀性能,且加工参数越大,改善程度越高;USRP试样经400℃保温2h后,表面晶粒有不同程度的长大,且表面微观应变值大幅降低;在不同摩擦条件下,试样表面的磨损机理有所不同,但总体而言,与磨光试样相比,USRP处理可以提高材料表面耐磨性,尤其是在润滑摩擦条件下,提高幅度显著。
Ultrasonic surface rolling processing (USRP) is put forward, in order to improvethe general properties of surfaces. Testing device includes the improved digitalultrasonic power supply (with more accuracy and stable frequency tracing andamplitude controlling systems) and USRP operator, in which, the processing tip isdesigned as a rolling ball, so that the service life can be greatly prolonged, whichmakes USRP more practical and economical.
Take as-supplied, quenched and tempered 40Cr steel as testing material. Analysismethods, including TEM, SEM, XRD, measurements of micro-hardness and surfaceroughness and so on, are used to discuss the micro structure and influence ofprocessing parameters on mechanical properties of USRP surfaces. Contrast tests ofthermal stability, corrosion and wear resistance are carried out to investigate theservice performance of USRP specimens.
Micro-structure observation and test results show that: USRP surface is of gradeddistribution; surface enhancement and grain refinement are the results of plasticdeformation accumulation. As for the quenched and tempered 40Cr specimen, theprecipitated and dispersion-distributed carbide strengthens the surfaces and anchorsthe dislocations. Nanocrystallization can be realized by USRP, with grain size of 3~7nm at the top surface and the nano-structured layer is about 100 micrometers thick.Diffraction patterns indicate that: solution of cementite takes place in a certain rangefrom top surface. Micro strain decreases by dislocation movements and grainboundary formation, so micro strain is not the biggest at the top surface.
USRP parameters have influence on surface hardening, surface roughness andresidual stress to some degree. Appropriate USRP treatment can reduce and eveneliminate the surface defects. However, repeated plastic deformation may damage thesurface, and micro-crack can be induced when processing energy exceeds the tensilestrength.
Contrast tests show that: USRP can make the breakdown potential and corrosionpotential of 40Cr specimens move positively, which indicates the improvement ofcorrosion resistance, and the bigger the parameters are, the better the corrosion
resistance will be. After annealing 2h at 400℃, surface grains grow up to some degree,and the surface micro strain decreases. Under different friction conditions, mechanismof wear surfaces varies. Generally speaking, USRP improves the wear resistance ofsurfaces, especially under lubricating, the increase is obvious.
引文
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