紫铜与低碳钢/铸铁堆焊层组织性能及界面扩散机理研究
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摘要
紫铜以其优良的耐蚀、减磨等物理化学性质，倍受青睐广为使用。阀门作为工业最为常用的部件应用十分广泛，而阀门密封面在其重复开关的过程中，极易受到介质的腐蚀和磨损，使阀门密封面受到损伤，影响其使用寿命。因此，开展阀门耐磨合材料的研究，可以延长阀门的使用寿命，从而达到提高经济效益的目的，具有重要的理论意义和应用价值。
本文采用等离子弧将紫铜堆焊到20g和HT200表面，并在堆焊过程中施加横向磁场，对比分析不同堆焊电流和磁场电流下堆焊层的成形性、硬度、耐磨性、耐蚀性和显微组织，并对堆焊界面的结合机理和扩散行为进行研究，明确堆焊电流和磁场电流对堆焊层组织性能的影响规律和作用机理。得到主要结论如下：
（1）对于无外加磁场作用的紫铜/低碳钢堆焊层而言，堆焊速度为120mm/min、送粉量为15g/min、堆焊电流为120A时，堆焊层的成形性最好，力学性能达到最佳值，此时硬度为58.05HV，磨损量为0.0118g，摩擦系数值为0.70，堆焊层的显微组织为细小等轴晶。当堆焊电流为100A时，堆焊层的腐蚀电位为-0.2778mv，耐蚀性最差；当堆焊电流增大为140A时，堆焊层的腐蚀电位也达到了最大值-0.1274mv，此时堆焊层的耐蚀性最好。
（2）对于无外加磁场作用的紫铜/铸铁堆焊层而言，当送粉量为15g/min、堆焊速度为120mm/min、堆焊电流选为120A时，堆焊层的成形性最好，力学性能达到最佳值，此时硬度为82.06HV，磨损量为最小值0.0147g，摩擦系数为0.73。堆焊电流为100A时，堆焊层的腐蚀电位为-0.3250mv，耐蚀性最差；当堆焊电流增大为140A时，堆焊层的腐蚀电位也达到了最大值-0.1762mv，此时堆焊层的耐蚀性最好。
（3）当外加磁场作用于堆焊过程时，对于紫铜/低碳钢堆焊层而言，堆焊电流为120A、磁场电流为2A时，堆焊层的成形性、力学性能和显微组织达到了最佳状态，此时的硬度为50.16HV，磨损量为0.0027g，摩擦系数为0.6，显微组织以相对细小的等轴晶为主；对于紫铜/铸铁堆焊层而言，堆焊电流为130A、磁场电流为2A时，堆焊层的力学性能和显微组织达到最佳状态，此时堆焊层的硬度为69.47HV，磨损量为0.0015g，摩擦系数为0.5，显微组织以相对细小的等轴晶为主。对于两种堆焊层耐蚀性的分析可以得出，无论堆焊电流为120A还是130A，其最佳的耐蚀状态均出现在磁场电流为2.5A时，此时的腐蚀电位分别为-0.126V和-0.102V。
（4）对于Cu-Fe二元金属的扩散，是遵循溶质再分配规律的。在较小的生长速率下，溶质原子可以进行充分扩散，使溶质Cu溶入Fe中，接近于平衡状态下的分凝系数；在较大的生长速率下，界面溶质扩散受到抑制，导致界面固相内溶质富集，溶质的分凝系数较平衡状态下要大。
（5）在外加磁场的作用下，等离子弧和液态熔池将发生旋转运动，形成电磁搅拌作用。电磁搅拌作用对于电弧的作用比较明显，但最终均作用于熔池，从而改变堆焊层晶粒的形核和长大过程。随着磁场电流的增大，所产生的磁感应强度也将增大，这促使堆焊层液态熔池中的磁扩散强度增大，促进元素的迁移和扩散，使堆焊层中组织均匀、成形美观，并可适当改善堆焊层的综合力学性能。
Red copper is widely used for its physical and chemical properties, such as excellentcorrosion resistance and antifriction. The valve which is the most commonly used inindustrial components has been widely applied. But sealing faces of valves are easy to becorroded and abraded in the process of its repeat switch，which were vulnerable to bedamaged and affect its service life. So it has important theory meaning and practice valueto research the resistant material which would prolong the lifetime of valves and increasethe economic performance.
Red copper is welding on the surface of20G and HT200with plasma arc undertransverse direction magnetic field. The comparison analysis of the formability, hardness,wearing resistance, erosion resistance, microstructure under different welding current andmagnetic field currentwas investigated by experimental method. And interfacing bondingmechanism of surfacing layer are tested and studied. The influence rule and actingmechanism of magnetic field currents and welding currents on properties andmicrostructure of surfacing layer are researched. The main results are as following:
（1）For red copper and low-carbon steel surfacing layer without external magneticfield, the formability of surfacing layer, mechanical properties has reached the bestcondition when the welding speed is120mm/min, powder feed rate is15g/min, weldingcurrent is120A.The hardness is58.05HV, wear extent is0.0118g, friction factor is0.70.At this time the microstructure of surfacing layer consists of small equiaxed grain. Thecorrosion resistance is worst when the welding current is100A and the corrosion potentialof the surfacing layer is-0.2778mv; The corrosion resistance is best when welding currentincreases to140A, and the corrosion potential surfacing layer has reached the maximum of-0.1274mv.
（2）For red copper and cast iron surfacing layer without external magnetic field, theformability of surfacing layer, mechanical properties has reached the best conditionwhenpowder feed rate equal to15g/min,welding speedequal to120mm/min, weldingcurrent equal to120A.At the moment, hardness is82.06HV, wear extent is minimum valueof0.0147g, fraction factor is0.73.The erosion resistance of surfacing layer is not goodwhen the welding current equal to100A,the corrosion potential equal to-0.3250mv. Theerosion resistance of surfacing layer is well when welding current increase to140A, thecorrosion potential reach to a maximum value of-0.1762mv.
（3）For red copper and low-carbon steel surfacing layer which magnetic field actedon it, the formability of surfacing layer, mechanical properties and microstructure hasreached the best condition when welding current equal to120A,magnetic field current equalto2A.At this time, hardness is50.16HV, wear extent is0.0027g, fraction factor is0.6, themicrostructure of surfacing layer consists ofrelatively smallequiaxedgrain. For red copperand cast iron surfacing layer, the formability of surfacing layer, mechanical properties andmicrostructure has reached the best condition when welding current equalto130A,magnetic field current equal to2A.At this time, hardness is69.47HV, wear extentis0.0015g, fraction factor is0.5, the microstructure of surfacing layer consists of relativelysmall equiaxedgrain. Regardless of the current for120A or130A, the erosion resistanceof surfacing layer is best when magnetic field current is2.5A, the corrosion potential is-0.126V and-0.102V.
（4）Following the law of solute redistribution, Cu-Fe binary metallic is submitted todiffuse. Under the small growth rate,solutes atoms can be fully spread, and dissolved theCu intoFe,make it close to the segregation coefficient in equilibrium state. Under the largegrowth rate, diffusion of the interface solute is restrained, whichcan lead to soluteenrichment within the solid state, and the solute segregation coefficient is larger thantheequilibriumstate.
（5）Induced by the extra magnetic field, plasma arc andliquid molten poolrotarymotion occurred which can formed electromagnetic stirring.Electromagnetic stirring hasthe positive effects on theelectric arc. It can act on molten pool, change surfacing layergrain nucleation and growth process. With the increasing of the magnetic field current,magnetic induction intensity will also raise. This causedmagnetic diffusion of surfacinglayer liquid molten poolincrease, the element migration and diffusion. It can also makesurfacing layer uniform and aesthetic, which can be appropriately to improve thecomprehensive mechanics performance of the surfacing layer.
本文采用等离子弧将紫铜堆焊到20g和HT200表面，并在堆焊过程中施加横向磁场，对比分析不同堆焊电流和磁场电流下堆焊层的成形性、硬度、耐磨性、耐蚀性和显微组织，并对堆焊界面的结合机理和扩散行为进行研究，明确堆焊电流和磁场电流对堆焊层组织性能的影响规律和作用机理。得到主要结论如下：
（1）对于无外加磁场作用的紫铜/低碳钢堆焊层而言，堆焊速度为120mm/min、送粉量为15g/min、堆焊电流为120A时，堆焊层的成形性最好，力学性能达到最佳值，此时硬度为58.05HV，磨损量为0.0118g，摩擦系数值为0.70，堆焊层的显微组织为细小等轴晶。当堆焊电流为100A时，堆焊层的腐蚀电位为-0.2778mv，耐蚀性最差；当堆焊电流增大为140A时，堆焊层的腐蚀电位也达到了最大值-0.1274mv，此时堆焊层的耐蚀性最好。
（2）对于无外加磁场作用的紫铜/铸铁堆焊层而言，当送粉量为15g/min、堆焊速度为120mm/min、堆焊电流选为120A时，堆焊层的成形性最好，力学性能达到最佳值，此时硬度为82.06HV，磨损量为最小值0.0147g，摩擦系数为0.73。堆焊电流为100A时，堆焊层的腐蚀电位为-0.3250mv，耐蚀性最差；当堆焊电流增大为140A时，堆焊层的腐蚀电位也达到了最大值-0.1762mv，此时堆焊层的耐蚀性最好。
（3）当外加磁场作用于堆焊过程时，对于紫铜/低碳钢堆焊层而言，堆焊电流为120A、磁场电流为2A时，堆焊层的成形性、力学性能和显微组织达到了最佳状态，此时的硬度为50.16HV，磨损量为0.0027g，摩擦系数为0.6，显微组织以相对细小的等轴晶为主；对于紫铜/铸铁堆焊层而言，堆焊电流为130A、磁场电流为2A时，堆焊层的力学性能和显微组织达到最佳状态，此时堆焊层的硬度为69.47HV，磨损量为0.0015g，摩擦系数为0.5，显微组织以相对细小的等轴晶为主。对于两种堆焊层耐蚀性的分析可以得出，无论堆焊电流为120A还是130A，其最佳的耐蚀状态均出现在磁场电流为2.5A时，此时的腐蚀电位分别为-0.126V和-0.102V。
（4）对于Cu-Fe二元金属的扩散，是遵循溶质再分配规律的。在较小的生长速率下，溶质原子可以进行充分扩散，使溶质Cu溶入Fe中，接近于平衡状态下的分凝系数；在较大的生长速率下，界面溶质扩散受到抑制，导致界面固相内溶质富集，溶质的分凝系数较平衡状态下要大。
（5）在外加磁场的作用下，等离子弧和液态熔池将发生旋转运动，形成电磁搅拌作用。电磁搅拌作用对于电弧的作用比较明显，但最终均作用于熔池，从而改变堆焊层晶粒的形核和长大过程。随着磁场电流的增大，所产生的磁感应强度也将增大，这促使堆焊层液态熔池中的磁扩散强度增大，促进元素的迁移和扩散，使堆焊层中组织均匀、成形美观，并可适当改善堆焊层的综合力学性能。
Red copper is widely used for its physical and chemical properties, such as excellentcorrosion resistance and antifriction. The valve which is the most commonly used inindustrial components has been widely applied. But sealing faces of valves are easy to becorroded and abraded in the process of its repeat switch，which were vulnerable to bedamaged and affect its service life. So it has important theory meaning and practice valueto research the resistant material which would prolong the lifetime of valves and increasethe economic performance.
Red copper is welding on the surface of20G and HT200with plasma arc undertransverse direction magnetic field. The comparison analysis of the formability, hardness,wearing resistance, erosion resistance, microstructure under different welding current andmagnetic field currentwas investigated by experimental method. And interfacing bondingmechanism of surfacing layer are tested and studied. The influence rule and actingmechanism of magnetic field currents and welding currents on properties andmicrostructure of surfacing layer are researched. The main results are as following:
（1）For red copper and low-carbon steel surfacing layer without external magneticfield, the formability of surfacing layer, mechanical properties has reached the bestcondition when the welding speed is120mm/min, powder feed rate is15g/min, weldingcurrent is120A.The hardness is58.05HV, wear extent is0.0118g, friction factor is0.70.At this time the microstructure of surfacing layer consists of small equiaxed grain. Thecorrosion resistance is worst when the welding current is100A and the corrosion potentialof the surfacing layer is-0.2778mv; The corrosion resistance is best when welding currentincreases to140A, and the corrosion potential surfacing layer has reached the maximum of-0.1274mv.
（2）For red copper and cast iron surfacing layer without external magnetic field, theformability of surfacing layer, mechanical properties has reached the best conditionwhenpowder feed rate equal to15g/min,welding speedequal to120mm/min, weldingcurrent equal to120A.At the moment, hardness is82.06HV, wear extent is minimum valueof0.0147g, fraction factor is0.73.The erosion resistance of surfacing layer is not goodwhen the welding current equal to100A,the corrosion potential equal to-0.3250mv. Theerosion resistance of surfacing layer is well when welding current increase to140A, thecorrosion potential reach to a maximum value of-0.1762mv.
（3）For red copper and low-carbon steel surfacing layer which magnetic field actedon it, the formability of surfacing layer, mechanical properties and microstructure hasreached the best condition when welding current equal to120A,magnetic field current equalto2A.At this time, hardness is50.16HV, wear extent is0.0027g, fraction factor is0.6, themicrostructure of surfacing layer consists ofrelatively smallequiaxedgrain. For red copperand cast iron surfacing layer, the formability of surfacing layer, mechanical properties andmicrostructure has reached the best condition when welding current equalto130A,magnetic field current equal to2A.At this time, hardness is69.47HV, wear extentis0.0015g, fraction factor is0.5, the microstructure of surfacing layer consists of relativelysmall equiaxedgrain. Regardless of the current for120A or130A, the erosion resistanceof surfacing layer is best when magnetic field current is2.5A, the corrosion potential is-0.126V and-0.102V.
（4）Following the law of solute redistribution, Cu-Fe binary metallic is submitted todiffuse. Under the small growth rate,solutes atoms can be fully spread, and dissolved theCu intoFe,make it close to the segregation coefficient in equilibrium state. Under the largegrowth rate, diffusion of the interface solute is restrained, whichcan lead to soluteenrichment within the solid state, and the solute segregation coefficient is larger thantheequilibriumstate.
（5）Induced by the extra magnetic field, plasma arc andliquid molten poolrotarymotion occurred which can formed electromagnetic stirring.Electromagnetic stirring hasthe positive effects on theelectric arc. It can act on molten pool, change surfacing layergrain nucleation and growth process. With the increasing of the magnetic field current,magnetic induction intensity will also raise. This causedmagnetic diffusion of surfacinglayer liquid molten poolincrease, the element migration and diffusion. It can also makesurfacing layer uniform and aesthetic, which can be appropriately to improve thecomprehensive mechanics performance of the surfacing layer.
引文
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