等离子喷涂耐磨涂层技术在大型薄壁零件上的应用研究
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摘要
陶瓷涂布刮刀是造纸工业中的关键零部件,也是易损耗件,需求量大,技术含量高。目前我国全部依赖进口,价格昂贵。本文针对陶瓷涂布刮刀制备技术中的两大难题：即大型薄壁零件上的耐磨陶瓷涂层制备工艺和刮刀涂层精密磨削工艺开展研究,初步取得的主要研究成果如下：
首次在国内制备出纳米复合涂层陶瓷涂布刮刀。针对长薄壁零部件易变形难控制的难点,结合大型薄壁零件的结构特点及喷涂要求对工艺进行优化设计：采用二因子试验及方差分析方法研究了喷砂距离、空气压力及两者的交互作用对涂布刮刀喷砂质量的影响,优化了薄壁零件喷砂工艺规范；采用正交试验方法研究了喷涂电流、喷涂电压、喷涂距离和送粉速率这四个关键参数对陶瓷涂层的孔隙率及刮刀平面度的影响规律,优化了大型薄壁零件上耐磨陶瓷涂层的等离子喷涂工艺；设计出刮刀钢带喷涂特种专用夹具,解决了薄壁零件喷涂过程中温升过快,容易变形的技术难题。
首次设计制造出刮刀涂层磨削专用工装夹具及磨削工艺方法,该工装夹具根据陶瓷涂布刮刀超长超薄难于精密加工的特点,利用小型精密磨床即可实现各个面的磨削,获得所需的几何形状和尺寸精度,并可以实现任意长度刮刀涂层的连续磨削。并探讨了涂层在磨削过程中的材料去除机理及磨削工艺参数的变化对涂层表面光洁度的影响。上述刮刀涂层在自行设计的专用磨削装备上精密磨削后,刮刀的直线度、平行度和表面粗糙度等关键性能指标均达到了行业标准所规定的精度要求,满足了在工业生产中应用的基本要求。
成功实现了在大型长薄零部件上获得高性能纳米、微米陶瓷复合涂层的技术。选用优化后的等离子喷涂工艺制备纳米及微米AT13(Al2O3-13%TiO2)涂层试样,并采用SEM、EPMA、TEM、XRD等现代分析手段对比研究了涂层组织、结构及成分分布特征；采用试验方法测定了涂层中的残余应力及分布特征、力学性能及耐磨粒磨损性能。分析表明：①等离子喷涂纳米及微米AT13涂层的组织致密,均匀,孔隙率低,结合强度高,两种涂层均能够满足在涂布刮刀上的应用要求。②两种涂层的主要相均为α-Al2O3、Υ-Al2O3及TiO2。纳米AT13涂层中则保留了较多的TiO2相。而微米AT13涂层中元素扩散现象显著,含有较多的Al2TiO5相,在两种涂层的富Al2O3区域均发现了非晶与纳米晶共存的现象。纳米AT13涂层呈现出典型的双态结构和晶粒细化现象。③等离子喷涂纳米及微米AT13涂层均为残余压应力状态,纳米AT13涂层由于部分熔融区增多,孔隙率相对较大,同时,涂层中的纳米晶出现聚集长大现象,改善了涂层中的应力状态,其残余压应力值显著低于微米涂层。④两种涂层的耐磨粒磨损性能优异,微米AT13陶瓷涂层的主要磨损方式为涂层中的微颗粒在磨削应力的作用下沿晶界的剥落和由于涂层中微裂纹的扩展而造成的涂层表面材料的小片状剥落；纳米陶瓷涂层的主要失效方式为微颗粒在磨削应力的作用下的沿晶界剥落。由于纳米陶瓷涂层的晶粒细小,晶界体积大,磨损过程中裂纹扩展路径更长,需要更多的能量,所以,其耐磨性能优于微米陶瓷涂层。
该研究对于加快我国造纸装备行业关键零部件-陶瓷刮刀的国产化进程,打破国际垄断,实现自主知识产权都具有重要的理论和现实意义。
As one of the key parts which are widely used in paper industry, ceramic coating blades are easy to be worn out and have large markets in our country. Now these kinds of high-tech products all rely on imports with expensive prices. Two major difficult problems in the preparation technology of ceramic coating blade were studied in this paper:One is the wear resistant ceramic coating preparation process on large thin-wall parts. The other is the precision grinding process of ceramic coating on blade. Main initial results are shown as follows:
Nano ceramic composite coating blades were prepared successfully for the first time in domestic. The preparing process parameters were designed and optimized according to structural featuresBy means of two factors orthogonal test and the variance analysis, the influences of sandblasting distance, air pressure and their interaction on sandblasting quality of coating blade was studied and the sandblasting process factor for thin wall parts were optimized. The influence rule of spraying current, voltage, spraying distance and powder feed rate on porosity of the ceramic coating and flatness of the blade was studied and the plasma spraying parameters of wear resistant ceramic coating on large thin-wall parts was optimized by adopting orthogonal experimentation. Special fixture was designed for plasma spraying on blade steel belt. By the aiding of this apparatus, the difficulties for spraying on thin wall parts such as excessive temperature rise and easy yielding were overcome.
According to ultra-long and ultra-thin structure features of ceramic coating blade which is difficult for precision finishing, special fixtureand the grinding process were designed firstly in home. By the aid of this fixture, each side of the blade can be grinded with a small precision grinding machine to get the necessary geometry and dimensional precision without the restriction of the coatmg bade length. Material removal mechanism and the effect of grinding parameters on coating surface finish were discussed. The key performance indexes of the coating blade such as straightness, parallelism and surface roughness all reach to the accuracy requirementThe preparation technology of high-performance nano and micron ceramic composite coatings on large, long and thin parts was realized successfully in this subject. Micron and nano-AT13 ceramic coating samples were prepared with optimized plasma spraying parameters. Microstructure, phases and components distribution of the two coatings were analyzed with the aid of modern analytical means such as scanning electron microscope, energy spectrum analysis, transmission electron microscope and X-ray diffraction. Residual stress and its distribution in the coatings, mechanical properties and abrasive wear resistance of the coatings were studied by experimental methods. The results showed:①Both of the nano and micron coatings prepared by plasma spraying process have dense and even microstructure, low porosity and higher bond strength. The two coatings all meet the application requirements of coating blade.②Main phases of the two coatings areα-Al2O3,Υ-Al2O3 and TiO2. More TiO2 phase was detected in nano AT13 coating. However, more Al2O3 phase was found in micron AT13 coating, mainly because the ceramic powders melt more fully and elements diffusion is more remarkable than that in nano AT13 coating. In rich Al2O3 region of the two coatings, amorphous and nanocrystalline structures were found. Nano AT 13 coating presents typical duplex microstructure and grain refinement phenomenon.③Both nano and micron AT13 coatings prepared by plasma spraying process are in residual compressive stress state. Because of the higher porosity and growing up phenomenon of nanocrystalline, the residual compressive stress in nano ceramic coating is released and lowers apparently than that of micron AT13 ceramic coating.④Both of the two coating have excellent abrasive wear resistant properties. Main failure pattern of micro AT13 coating is the tiny grains spalling along crystal boundary and the flake layer fragmenting caused by micro cracks expansion at the action of grinding stress. Main failure pattern of nano AT13 coating is the tiny grains spalling along crystal boundary. Because the grain size of nano AT13 coating is tinier and the grain boundary area is larger, more energy is needed for micro cracks expansion. So the abrasive wear resistance of nano AT 13 coating is superior to that of micron coating,
has an important theoretical and practical significance onnationalization of the key parts in paper industry-ceramic coating blade, breaking the international monopoly in this field and realizing the independent intellectual property rights.
首次在国内制备出纳米复合涂层陶瓷涂布刮刀。针对长薄壁零部件易变形难控制的难点,结合大型薄壁零件的结构特点及喷涂要求对工艺进行优化设计：采用二因子试验及方差分析方法研究了喷砂距离、空气压力及两者的交互作用对涂布刮刀喷砂质量的影响,优化了薄壁零件喷砂工艺规范；采用正交试验方法研究了喷涂电流、喷涂电压、喷涂距离和送粉速率这四个关键参数对陶瓷涂层的孔隙率及刮刀平面度的影响规律,优化了大型薄壁零件上耐磨陶瓷涂层的等离子喷涂工艺；设计出刮刀钢带喷涂特种专用夹具,解决了薄壁零件喷涂过程中温升过快,容易变形的技术难题。
首次设计制造出刮刀涂层磨削专用工装夹具及磨削工艺方法,该工装夹具根据陶瓷涂布刮刀超长超薄难于精密加工的特点,利用小型精密磨床即可实现各个面的磨削,获得所需的几何形状和尺寸精度,并可以实现任意长度刮刀涂层的连续磨削。并探讨了涂层在磨削过程中的材料去除机理及磨削工艺参数的变化对涂层表面光洁度的影响。上述刮刀涂层在自行设计的专用磨削装备上精密磨削后,刮刀的直线度、平行度和表面粗糙度等关键性能指标均达到了行业标准所规定的精度要求,满足了在工业生产中应用的基本要求。
成功实现了在大型长薄零部件上获得高性能纳米、微米陶瓷复合涂层的技术。选用优化后的等离子喷涂工艺制备纳米及微米AT13(Al2O3-13%TiO2)涂层试样,并采用SEM、EPMA、TEM、XRD等现代分析手段对比研究了涂层组织、结构及成分分布特征；采用试验方法测定了涂层中的残余应力及分布特征、力学性能及耐磨粒磨损性能。分析表明：①等离子喷涂纳米及微米AT13涂层的组织致密,均匀,孔隙率低,结合强度高,两种涂层均能够满足在涂布刮刀上的应用要求。②两种涂层的主要相均为α-Al2O3、Υ-Al2O3及TiO2。纳米AT13涂层中则保留了较多的TiO2相。而微米AT13涂层中元素扩散现象显著,含有较多的Al2TiO5相,在两种涂层的富Al2O3区域均发现了非晶与纳米晶共存的现象。纳米AT13涂层呈现出典型的双态结构和晶粒细化现象。③等离子喷涂纳米及微米AT13涂层均为残余压应力状态,纳米AT13涂层由于部分熔融区增多,孔隙率相对较大,同时,涂层中的纳米晶出现聚集长大现象,改善了涂层中的应力状态,其残余压应力值显著低于微米涂层。④两种涂层的耐磨粒磨损性能优异,微米AT13陶瓷涂层的主要磨损方式为涂层中的微颗粒在磨削应力的作用下沿晶界的剥落和由于涂层中微裂纹的扩展而造成的涂层表面材料的小片状剥落；纳米陶瓷涂层的主要失效方式为微颗粒在磨削应力的作用下的沿晶界剥落。由于纳米陶瓷涂层的晶粒细小,晶界体积大,磨损过程中裂纹扩展路径更长,需要更多的能量,所以,其耐磨性能优于微米陶瓷涂层。
该研究对于加快我国造纸装备行业关键零部件-陶瓷刮刀的国产化进程,打破国际垄断,实现自主知识产权都具有重要的理论和现实意义。
As one of the key parts which are widely used in paper industry, ceramic coating blades are easy to be worn out and have large markets in our country. Now these kinds of high-tech products all rely on imports with expensive prices. Two major difficult problems in the preparation technology of ceramic coating blade were studied in this paper:One is the wear resistant ceramic coating preparation process on large thin-wall parts. The other is the precision grinding process of ceramic coating on blade. Main initial results are shown as follows:
Nano ceramic composite coating blades were prepared successfully for the first time in domestic. The preparing process parameters were designed and optimized according to structural featuresBy means of two factors orthogonal test and the variance analysis, the influences of sandblasting distance, air pressure and their interaction on sandblasting quality of coating blade was studied and the sandblasting process factor for thin wall parts were optimized. The influence rule of spraying current, voltage, spraying distance and powder feed rate on porosity of the ceramic coating and flatness of the blade was studied and the plasma spraying parameters of wear resistant ceramic coating on large thin-wall parts was optimized by adopting orthogonal experimentation. Special fixture was designed for plasma spraying on blade steel belt. By the aiding of this apparatus, the difficulties for spraying on thin wall parts such as excessive temperature rise and easy yielding were overcome.
According to ultra-long and ultra-thin structure features of ceramic coating blade which is difficult for precision finishing, special fixtureand the grinding process were designed firstly in home. By the aid of this fixture, each side of the blade can be grinded with a small precision grinding machine to get the necessary geometry and dimensional precision without the restriction of the coatmg bade length. Material removal mechanism and the effect of grinding parameters on coating surface finish were discussed. The key performance indexes of the coating blade such as straightness, parallelism and surface roughness all reach to the accuracy requirementThe preparation technology of high-performance nano and micron ceramic composite coatings on large, long and thin parts was realized successfully in this subject. Micron and nano-AT13 ceramic coating samples were prepared with optimized plasma spraying parameters. Microstructure, phases and components distribution of the two coatings were analyzed with the aid of modern analytical means such as scanning electron microscope, energy spectrum analysis, transmission electron microscope and X-ray diffraction. Residual stress and its distribution in the coatings, mechanical properties and abrasive wear resistance of the coatings were studied by experimental methods. The results showed:①Both of the nano and micron coatings prepared by plasma spraying process have dense and even microstructure, low porosity and higher bond strength. The two coatings all meet the application requirements of coating blade.②Main phases of the two coatings areα-Al2O3,Υ-Al2O3 and TiO2. More TiO2 phase was detected in nano AT13 coating. However, more Al2O3 phase was found in micron AT13 coating, mainly because the ceramic powders melt more fully and elements diffusion is more remarkable than that in nano AT13 coating. In rich Al2O3 region of the two coatings, amorphous and nanocrystalline structures were found. Nano AT 13 coating presents typical duplex microstructure and grain refinement phenomenon.③Both nano and micron AT13 coatings prepared by plasma spraying process are in residual compressive stress state. Because of the higher porosity and growing up phenomenon of nanocrystalline, the residual compressive stress in nano ceramic coating is released and lowers apparently than that of micron AT13 ceramic coating.④Both of the two coating have excellent abrasive wear resistant properties. Main failure pattern of micro AT13 coating is the tiny grains spalling along crystal boundary and the flake layer fragmenting caused by micro cracks expansion at the action of grinding stress. Main failure pattern of nano AT13 coating is the tiny grains spalling along crystal boundary. Because the grain size of nano AT13 coating is tinier and the grain boundary area is larger, more energy is needed for micro cracks expansion. So the abrasive wear resistance of nano AT 13 coating is superior to that of micron coating,
has an important theoretical and practical significance onnationalization of the key parts in paper industry-ceramic coating blade, breaking the international monopoly in this field and realizing the independent intellectual property rights.
引文
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