减摩耐磨多层膜设计及研究进展
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摘要
涂层作为一种有效的表面改性技术,具有材料选择范围广、性能可调节性好的优点,适用于多种工况和结构要求,在零部件的减摩耐磨中得到了广泛的应用。传统的单一涂层分为减摩涂层和耐磨涂层两类。前者采用类石墨层状结构润滑材料制备,用于减小摩擦副的摩擦系数,但磨损率较高;后者则采用陶瓷等高硬材料制备,用于抵抗磨损、保护基体材料,但摩擦系数较大。这两种涂层在使用中都不能同时发挥减摩、耐磨的作用。随着机械、航天等领域的不断发展,在不能采用传统油润滑的特殊环境中,传统涂层无法同时满足零部件之间较小的摩擦系数和较低的磨损率的要求。而多层膜结合选材和层状结构设计,兼具减摩、耐磨作用,其相关研究为解决材料摩擦学性能不足这一关键问题提供了可能。构筑多层膜的基本原理是采用磁控溅射等手段,在基体材料上制备软硬交替分布的层状结构涂层,单层厚度在微米和纳米级之间。其摩擦学性能取决于自身的结构参数和制备工艺参数,二者通过改变多层膜的结晶状态、力学性能进而影响其摩擦学性能。如何优化结构、工艺参数以获得最佳的减摩耐磨性能是目前亟待解决的主要问题,相关研究集中在三个方面:一是控制多层膜的晶粒生长和晶体择优取向;二是提高多层膜的韧性;三是降低多层膜的残余应力。通过优化结构、工艺参数,控制制备过程中的不良因素,强化有利因素,多层膜的摩擦学性能得到了进一步提升。研究表明,调整多层膜中的单层膜厚度可以实现内部材料结晶状态的演变及抑制晶体取向的转变。另外,多层膜层状结构产生的大量界面可以在涂层受载产生裂纹时吸收能量,抑制或偏转裂纹扩展,因此可以通过引入高质量层间界面优化其韧性。多层膜制备过程中产生的残余应力随溅射过程逐渐累积,降低基片偏压是控制残余应力的有效手段;多层膜的层状结构可以打断残余应力的累积,也能从时间效应上控制残余应力。从研究成果来看,影响多层膜摩擦学性能的因素存在最佳值。从实验数据来看,大气环境中干摩擦磨损率可以降至3×10-10mm3/(N·m),并且摩擦系数始终稳定在0.1左右。本文归纳了多层膜的研究现状,主要从设计原则(包括影响因素和控制方法)、性能表征和检测手段、近期研究成果三个方面进行阐述和分析。指出目前多层膜研究中面临的问题,并对未来的研究方向进行展望,以期为相关学者提供参考。
Coating is considered to be an effective surface modification technology by virtue of its wide material selection range and fine property adjustability,which is suitable for various working conditions and structural requirements,thus having found wide application in antifriction and wear-resistance of machine parts. Traditional single coating can be classified into anti-friction coating and wear-resistant coating. The former was prepared by graphite-like layer-structured lubricating materials that can reduce the friction coefficient of the friction pair but behave badly in the wear rate,whereas the properties of the latter prepared by high-hardness materials such as ceramics are completely adverse to the former's.Hence neither of them can be effective in both friction reduction and wear resistance. With the continuous development of the machinery and aerospace,traditional coatings cannot attain the requirement of low friction coefficients and low wear rates under specific environments where traditional lubricating oil is unavailable. Multilayer coatings ensure both lubrication and wear-resistance with proper material selection and layered structure design,and relevant researches offer significant insights in solving the critical issue of the inferior tribological properties of materials.The basic principle of designing the multilayer coatings is to prepare layer structured coatings with alternating soft and hard layers on the substrate via magnetron sputtering or the others,and the thickness of a monolayer is at micron and nanometer scale. The tribological properties of multilayer coatings depend on its own structural parameters and preparation process parameters. These two factors take effect by changing the crystalline state and mechanical properties of multilayer coatings. The current problem demanding prompt solution is to acquire the best tribological properties of friction reduction and wear resistance by optimizing structural parameters and technological parameters. Specifically,the following three aspects are the focus of current researches: The first is to control the grain growth and crystal orientation of multilayer coatings,the second is to improve the toughness of multilayer coatings and the third is to reduce the residual stress of multilayer coatings. Further improvement on tribological properties of multilayer coatings has been achieved by optimizing the structural and technological parameters which enables inhibited unfavorable factors and strengthened favorable factors.Sufficient investigations indicate that adjusting the thickness of monolayer in multilayer coatings can realize the evolution of crystalline state,and suppress the transformation of the crystal orientation. In addition,number of interfaces produced by the layered structure of multilayer coatings can absorb energy and inhibit or deflect crack propagation when the multilayer coatings are loaded with cracks. Therefore,the toughness of coatings can be optimized through introducing a high quality interface. Reducing the substrate bias is an effective method to control residual stress generated during coating preparation,and the accumulation of residual stress can be interrupted by layered structure of the multilayer coatings along sputtering process. According to the research results,there are optimal values for the factors affecting the tribological properties of multilayer coatings. Experimental datas reveal that the wear rate of dry friction in the atmospheric environment can be lowered to 3×10-10 mm3/( N·m),and the friction coefficient remains stable around 0.1.This paper summarizes the research status with respect to multilayer coatings,and mainly analyzes from three aspects: design principles( including influence factors and control methods),performance characterization and detection methods,and recent research outputs. We then pay attention to the inadequacy of previous researches and the prospective research directions in the future,and expect our review to provide references for relevant scholars.
Coating is considered to be an effective surface modification technology by virtue of its wide material selection range and fine property adjustability,which is suitable for various working conditions and structural requirements,thus having found wide application in antifriction and wear-resistance of machine parts. Traditional single coating can be classified into anti-friction coating and wear-resistant coating. The former was prepared by graphite-like layer-structured lubricating materials that can reduce the friction coefficient of the friction pair but behave badly in the wear rate,whereas the properties of the latter prepared by high-hardness materials such as ceramics are completely adverse to the former's.Hence neither of them can be effective in both friction reduction and wear resistance. With the continuous development of the machinery and aerospace,traditional coatings cannot attain the requirement of low friction coefficients and low wear rates under specific environments where traditional lubricating oil is unavailable. Multilayer coatings ensure both lubrication and wear-resistance with proper material selection and layered structure design,and relevant researches offer significant insights in solving the critical issue of the inferior tribological properties of materials.The basic principle of designing the multilayer coatings is to prepare layer structured coatings with alternating soft and hard layers on the substrate via magnetron sputtering or the others,and the thickness of a monolayer is at micron and nanometer scale. The tribological properties of multilayer coatings depend on its own structural parameters and preparation process parameters. These two factors take effect by changing the crystalline state and mechanical properties of multilayer coatings. The current problem demanding prompt solution is to acquire the best tribological properties of friction reduction and wear resistance by optimizing structural parameters and technological parameters. Specifically,the following three aspects are the focus of current researches: The first is to control the grain growth and crystal orientation of multilayer coatings,the second is to improve the toughness of multilayer coatings and the third is to reduce the residual stress of multilayer coatings. Further improvement on tribological properties of multilayer coatings has been achieved by optimizing the structural and technological parameters which enables inhibited unfavorable factors and strengthened favorable factors.Sufficient investigations indicate that adjusting the thickness of monolayer in multilayer coatings can realize the evolution of crystalline state,and suppress the transformation of the crystal orientation. In addition,number of interfaces produced by the layered structure of multilayer coatings can absorb energy and inhibit or deflect crack propagation when the multilayer coatings are loaded with cracks. Therefore,the toughness of coatings can be optimized through introducing a high quality interface. Reducing the substrate bias is an effective method to control residual stress generated during coating preparation,and the accumulation of residual stress can be interrupted by layered structure of the multilayer coatings along sputtering process. According to the research results,there are optimal values for the factors affecting the tribological properties of multilayer coatings. Experimental datas reveal that the wear rate of dry friction in the atmospheric environment can be lowered to 3×10-10 mm3/( N·m),and the friction coefficient remains stable around 0.1.This paper summarizes the research status with respect to multilayer coatings,and mainly analyzes from three aspects: design principles( including influence factors and control methods),performance characterization and detection methods,and recent research outputs. We then pay attention to the inadequacy of previous researches and the prospective research directions in the future,and expect our review to provide references for relevant scholars.
引文
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