高频感应熔覆制备耐蚀耐磨涂层研究
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摘要
为了解决抽油杆的腐蚀磨损问题,延长其使用寿命,使用高频感应加热技术对抽油杆调质处理时在其表面冷涂覆耐蚀耐磨覆层使之与抽油杆形成冶金结合,由于熔覆过程难以控制,表面涂层容易流淌,成型较差,基于此本文运用有限元软件ANSYS对不同工艺的高频感应熔覆温度场进行数值模拟,得到感应重熔时涂层和基体表面之间感应磁场和温度场的分布图;分析了感应重熔工艺参数对模拟结果的影响,找到了较好的工艺参数;最后以数值模拟的结果为参考进行试验研究,将模拟得到的工艺参数运用到试验中。试验中,采用镍基合金中加入3%,6%,9%的稀土镧氧化物以改善冷涂法制备涂层的表面成型困难和孔隙率高等问题,并结合高频感应加热与超音速火焰喷涂技术在抽油杆表面用钢制备涂层,利用OP、XRD、SEM、EPMA手段分别对上述两种方法制备的涂层组织、基体和涂层结合处的亚结构与电化学腐蚀、冲蚀磨损性能测试与研究。
结果表明,感应加热瞬间在基体表面和涂层近表面分别有电磁密度、功率密度较高的区域,在感应加热频率为100KHz时,工作电流为1400A,处理时间为14S时,获得NiCrBSi熔覆涂层质量最高,当在镍基涂层加入6%的稀土镧氧化物,涂层的耐蚀和耐冲蚀磨损性能最好,阳极腐蚀电流为16.34 A/cm2,在90°角冲蚀90min后涂层失重仅为2.11 mg/mm2,在熔覆过程中涂层元素与基体元素在高温下发生扩散,并在界面处形成白亮带,界面的主要成分Ni、Fe固溶体、铁的碳、硼化物;超音速火焰喷涂层经感应重熔后,涂层与基体形成冶金结合,消除了涂层中的层状结构,其耐蚀和耐磨性能大大提高,而且其组织与性能均优于冷涂法制备的涂层。
To extend the life of sucker rod against the corrosion and wear, during quenching & tempering sucker rod using high frequency induction heating technology, the sucker rod is coated anticorrosion and anti-wear coating by cooling coating, and make them metallurgy integrate. Because it is difficult to control cladding technique, layer of surface flows easily, besides surface forming is poor. According to all the reasons listed above, the transient temperature field of different technique of high frequency induction cladding is simulated. The induction magnetic field and the transient temperature distributing between the substrate surface and the coating at the moment of induction heating is obtained. The influence of the technical parameters on the induction heating simulation result is analyzed, and appropriate technical parameters are found. Experiments are carried out according to the numerical simulation results, and the technical parameters obtained from the simulation are used in the experiments. The control factors of the induction heating are studied, the optimum technical condition for induction cladding is found. During experiment, we add 3%,6%,9% rare earth lanthanum oxide to Ni-based alloy in order to improve surface forming poor and high porosity of coating by cool-coated and manufactured coating onto the sucker rod steel integrate high frequency induction heating technology with HVOF technology. Meanwhile XRD, SEM , EPMA and OM analytical methods were utilized to analyze microstructure of cladding coating, to test electrochemistry corrosion and erosion and corrosion wear.
The results indicated that the induction frequency is 100 KHz, work current is 1400 A, time of induction heat treatment is 14s, the quality of cladding coating is the highest than other techniques, when Ni-based alloy is added 6% rare earth lanthanum oxide, anticorrosion and anti-wear property of the coating gained is best, and anodic corrosion current is16.34 A/cm2, at 90°jet angle erosive wear weight loss is 2.11 mg/mm2 in 90 min, while cladding, element of coating and substrate diffuse each other under high temperature, meanwhile interface between substrate and coating form white light strip, and main component of interface are Ni-Fe solid solutions, boride and carbide iron. HVOF coatings after induction cladding, the coating and substrate make metallurgy bonding, eliminating layer structure, its corrosion and wear resistance are greatly improved and its structure and property is better than cool-coated.
结果表明,感应加热瞬间在基体表面和涂层近表面分别有电磁密度、功率密度较高的区域,在感应加热频率为100KHz时,工作电流为1400A,处理时间为14S时,获得NiCrBSi熔覆涂层质量最高,当在镍基涂层加入6%的稀土镧氧化物,涂层的耐蚀和耐冲蚀磨损性能最好,阳极腐蚀电流为16.34 A/cm2,在90°角冲蚀90min后涂层失重仅为2.11 mg/mm2,在熔覆过程中涂层元素与基体元素在高温下发生扩散,并在界面处形成白亮带,界面的主要成分Ni、Fe固溶体、铁的碳、硼化物;超音速火焰喷涂层经感应重熔后,涂层与基体形成冶金结合,消除了涂层中的层状结构,其耐蚀和耐磨性能大大提高,而且其组织与性能均优于冷涂法制备的涂层。
To extend the life of sucker rod against the corrosion and wear, during quenching & tempering sucker rod using high frequency induction heating technology, the sucker rod is coated anticorrosion and anti-wear coating by cooling coating, and make them metallurgy integrate. Because it is difficult to control cladding technique, layer of surface flows easily, besides surface forming is poor. According to all the reasons listed above, the transient temperature field of different technique of high frequency induction cladding is simulated. The induction magnetic field and the transient temperature distributing between the substrate surface and the coating at the moment of induction heating is obtained. The influence of the technical parameters on the induction heating simulation result is analyzed, and appropriate technical parameters are found. Experiments are carried out according to the numerical simulation results, and the technical parameters obtained from the simulation are used in the experiments. The control factors of the induction heating are studied, the optimum technical condition for induction cladding is found. During experiment, we add 3%,6%,9% rare earth lanthanum oxide to Ni-based alloy in order to improve surface forming poor and high porosity of coating by cool-coated and manufactured coating onto the sucker rod steel integrate high frequency induction heating technology with HVOF technology. Meanwhile XRD, SEM , EPMA and OM analytical methods were utilized to analyze microstructure of cladding coating, to test electrochemistry corrosion and erosion and corrosion wear.
The results indicated that the induction frequency is 100 KHz, work current is 1400 A, time of induction heat treatment is 14s, the quality of cladding coating is the highest than other techniques, when Ni-based alloy is added 6% rare earth lanthanum oxide, anticorrosion and anti-wear property of the coating gained is best, and anodic corrosion current is16.34 A/cm2, at 90°jet angle erosive wear weight loss is 2.11 mg/mm2 in 90 min, while cladding, element of coating and substrate diffuse each other under high temperature, meanwhile interface between substrate and coating form white light strip, and main component of interface are Ni-Fe solid solutions, boride and carbide iron. HVOF coatings after induction cladding, the coating and substrate make metallurgy bonding, eliminating layer structure, its corrosion and wear resistance are greatly improved and its structure and property is better than cool-coated.
引文
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