泡沫镍/聚四氟乙烯机械密封复合材料及摩擦学行为研究
摘要
船用机械密封是船舶推进系统的重要组成部分之一。国内外机械密封的研究主要集中在密封面的失效分析、静动环端而间的热效应、摩擦磨损形貌和改进静环材料与制备工艺上。通过对静环密封面的摩擦磨损性能研究可为机械密封系统的设计提供重要依据,从性能或是结构方面都能使设计者有的放矢,减少人力和资源的浪费。
本文以船用机械密封静环材料为应用背景,对端面材料进行了设计与制备。以设计的聚合物基复合材料为主要研究对象,开展了复合材料设计与工艺研究、网状与颗粒项共混复合材料的摩擦行为、磨损机理以及密封端面受力分析。通过研究,证明了泡沫镍能有效提高聚四氟乙烯的力学与摩擦学性能,特别是耐磨性能。本文的主要工作及成果是：
1.泡沫镍／聚四氟乙烯复合材料的设计与制备工艺研究。通过实验确定制备密封面原材料配比。确定以聚四氟乙烯作为复合材料基体,泡沫镍为骨架材料,碳纳米管和金刚石微粉为功能性填料。采用高温裂解工艺,将碳纳米管沉积于泡沫镍表面,以提高碳纳米管的分散性能。金刚石微粉、预处理后的泡沫镍与聚四氟乙烯共混高温固化,制得泡沫镍／聚四氟乙烯复合材料。该材料使用连续网状材料作为增强剂不受填料排列方向影响,并具有较好的自润滑性能。
2.泡沫镍／聚四氟乙烯复合材料力学性能与滑动摩擦特性研究。通过试验考察了不同质量配比的泡沫镍／聚四氟乙烯复合材料,发现此种复合材料的力学性能与泡沫镍的含量成正比。碳纳米管通过沉积的方式混合解决了纳米材料分散不均匀问题,并能提高填料与基体的结合强度。三维形态泡沫镍与纤维或颗粒填料增强的复合材料相比较,它不受填料的排列方向影响。在提高力学性能的同时也能获得稳定较低的摩擦系数。
3.泡沫镍／聚四氟乙烯复合材料的磨损特性与机理研究。利用磨损试验对材料的磨损率进行记录；扫描电子显微镜对形貌进行分析；X射线衍射对磨损产物定性,重点分析该复合材料的磨损性能。研究复合材料中填料的磨损机理与特性。对复合材料在滑动摩擦过程中沉积于对磨件上的薄膜—转移膜,进行了生成量、物相和特性研究。
4.泡沫镍／聚四氟乙烯复合材料的蠕变行为研究。应力以压缩方式对材料进行了蠕变性能测试,及温度对蠕变性能的影响。利用压缩蠕变测试结果,对比常用粘弹性模型后。选用广义Kelvin五参数与Brugers模型,分别计算得出复合材料的蠕变模型参数。
5.机械密封接端面接触应力与热传导数值模拟分析。讨论了船用机械密封的运转特点。结合必要的假设对密封体系简化,分析推导出端面间的受力。最后利用有限元方法对其接触时的特征进行详细讨论。计算模型采用实际机械密封结构尺寸；选用本文研制的泡沫镍／聚四氟乙烯材料参数,计算分析了密封结构接触运转下的应力、应变分布规律。
Marine mechanical seal is one of the major parts of the marine propulsion system. Mechanical seal research on domestic and overseas is mainly concentrated on the researches of sealing surface in failure analysis, the static thermal effects, where morphology and preparation process of sealing materials. As mutual friction mechanical part, no matter on which kinds of materials manufacturing sealing surface, friction and wear performance should be studied. Friction and wear performance research of the stationary ring can provide an important basis for the design, reduce the waste of manpower and resources, make designers earlier realize performance and structural requirements. This thesis according to the operation characteristics and strength requirements of marine mechanical seal designed and prepared a kind of seal face materials. Designed polymer matrix composites are the main object of study, the content is seal face stress analysis, composite material design and preparation process, mesh metal and particles fillers theoretical studies of the wear mechanism.
1. On the basis of the sealing interface operating characteristics and failure causes, by the experiment determined the ratio of raw materials for prepared the sealing surface composite, the pre-processing of raw materials and molding process also made a thorough study. The high temperature pyrolysis process was determined, under the conditions of550℃nanotubes (CNTs) deposited on mesh material foamed nickel. After mixing diamond micro powder after3-4times procuring then raised the temperature to280℃for heat preservation two hours completely solidify molding, finally obtained nickel foam/PTFE composites-seal face material.
2. Experiment tested the effects between different mass ratios of the foamed Ni/PTFE composite material; found that the mechanical properties of such composites are a direct ratio to the amount of nickel foam. Compared with the fibers or particulate filler, metal mesh which has a three-dimensional shape was not impacted by arrangement direction. It simply related to the content of the nickel foam for enhancing the mechanical properties. But when higher the content of nickel foam the coefficient of friction will also increase accordingly. The synergy effect between nickel foam and diamond micro powder fillers in mechanical friction performance will be weakened with increasing nickel foam filler content.
3. Wear experiment records the wear rate of the material; scanning electron microscopy(SEM) analysis of the morphology; X-ray diffraction(XRD) qualitative wear product of the other couple, analysis focus on the wear properties and study on wear mechanisms and characteristics of the composite filter. Also research of deposition characteristics generated in sliding friction process.
4. The creep performance of foam Nickel/PTFE composite was tested by compressive creep test mostly close to the actual mechanical seal interface operating. Using the compression creep test results substitution in commonly viscoelastic model for compared accuracy rate. Selection of the generalized Kelvin five parameters model and the Brugers model, calculated the creep parameters of the composite model respectively.
5. Discussion on the marine mechanical seal operating characteristics, combined with basic and necessary assumption condition for simplifies the force on the end faces in sealing system. Finally, using the finite element method discussed contact characteristics in detail. The model is calculated by the actual mechanical seal structure; selected foam Nickel/PTFE composite material parameters used for the calculation of the simulation process analysis. The main content of the simulation is material contact stress in the operation process and strain distribution with the heat conduction rule.
By researching proven mesh nickel foam can reinforce material effectively improve the mechanical and technological properties of the composites, especially the wear resistance. However, along with the broaden engineering friction and wear applications, in the field of polymer matrix composites, explore the mesh material (three-dimensional morphology) packing as well as the synthesis of functional filler composite material, friction characteristics, mechanism of failure modes and other issues needs further explored.
本文以船用机械密封静环材料为应用背景,对端面材料进行了设计与制备。以设计的聚合物基复合材料为主要研究对象,开展了复合材料设计与工艺研究、网状与颗粒项共混复合材料的摩擦行为、磨损机理以及密封端面受力分析。通过研究,证明了泡沫镍能有效提高聚四氟乙烯的力学与摩擦学性能,特别是耐磨性能。本文的主要工作及成果是：
1.泡沫镍／聚四氟乙烯复合材料的设计与制备工艺研究。通过实验确定制备密封面原材料配比。确定以聚四氟乙烯作为复合材料基体,泡沫镍为骨架材料,碳纳米管和金刚石微粉为功能性填料。采用高温裂解工艺,将碳纳米管沉积于泡沫镍表面,以提高碳纳米管的分散性能。金刚石微粉、预处理后的泡沫镍与聚四氟乙烯共混高温固化,制得泡沫镍／聚四氟乙烯复合材料。该材料使用连续网状材料作为增强剂不受填料排列方向影响,并具有较好的自润滑性能。
2.泡沫镍／聚四氟乙烯复合材料力学性能与滑动摩擦特性研究。通过试验考察了不同质量配比的泡沫镍／聚四氟乙烯复合材料,发现此种复合材料的力学性能与泡沫镍的含量成正比。碳纳米管通过沉积的方式混合解决了纳米材料分散不均匀问题,并能提高填料与基体的结合强度。三维形态泡沫镍与纤维或颗粒填料增强的复合材料相比较,它不受填料的排列方向影响。在提高力学性能的同时也能获得稳定较低的摩擦系数。
3.泡沫镍／聚四氟乙烯复合材料的磨损特性与机理研究。利用磨损试验对材料的磨损率进行记录；扫描电子显微镜对形貌进行分析；X射线衍射对磨损产物定性,重点分析该复合材料的磨损性能。研究复合材料中填料的磨损机理与特性。对复合材料在滑动摩擦过程中沉积于对磨件上的薄膜—转移膜,进行了生成量、物相和特性研究。
4.泡沫镍／聚四氟乙烯复合材料的蠕变行为研究。应力以压缩方式对材料进行了蠕变性能测试,及温度对蠕变性能的影响。利用压缩蠕变测试结果,对比常用粘弹性模型后。选用广义Kelvin五参数与Brugers模型,分别计算得出复合材料的蠕变模型参数。
5.机械密封接端面接触应力与热传导数值模拟分析。讨论了船用机械密封的运转特点。结合必要的假设对密封体系简化,分析推导出端面间的受力。最后利用有限元方法对其接触时的特征进行详细讨论。计算模型采用实际机械密封结构尺寸；选用本文研制的泡沫镍／聚四氟乙烯材料参数,计算分析了密封结构接触运转下的应力、应变分布规律。
Marine mechanical seal is one of the major parts of the marine propulsion system. Mechanical seal research on domestic and overseas is mainly concentrated on the researches of sealing surface in failure analysis, the static thermal effects, where morphology and preparation process of sealing materials. As mutual friction mechanical part, no matter on which kinds of materials manufacturing sealing surface, friction and wear performance should be studied. Friction and wear performance research of the stationary ring can provide an important basis for the design, reduce the waste of manpower and resources, make designers earlier realize performance and structural requirements. This thesis according to the operation characteristics and strength requirements of marine mechanical seal designed and prepared a kind of seal face materials. Designed polymer matrix composites are the main object of study, the content is seal face stress analysis, composite material design and preparation process, mesh metal and particles fillers theoretical studies of the wear mechanism.
1. On the basis of the sealing interface operating characteristics and failure causes, by the experiment determined the ratio of raw materials for prepared the sealing surface composite, the pre-processing of raw materials and molding process also made a thorough study. The high temperature pyrolysis process was determined, under the conditions of550℃nanotubes (CNTs) deposited on mesh material foamed nickel. After mixing diamond micro powder after3-4times procuring then raised the temperature to280℃for heat preservation two hours completely solidify molding, finally obtained nickel foam/PTFE composites-seal face material.
2. Experiment tested the effects between different mass ratios of the foamed Ni/PTFE composite material; found that the mechanical properties of such composites are a direct ratio to the amount of nickel foam. Compared with the fibers or particulate filler, metal mesh which has a three-dimensional shape was not impacted by arrangement direction. It simply related to the content of the nickel foam for enhancing the mechanical properties. But when higher the content of nickel foam the coefficient of friction will also increase accordingly. The synergy effect between nickel foam and diamond micro powder fillers in mechanical friction performance will be weakened with increasing nickel foam filler content.
3. Wear experiment records the wear rate of the material; scanning electron microscopy(SEM) analysis of the morphology; X-ray diffraction(XRD) qualitative wear product of the other couple, analysis focus on the wear properties and study on wear mechanisms and characteristics of the composite filter. Also research of deposition characteristics generated in sliding friction process.
4. The creep performance of foam Nickel/PTFE composite was tested by compressive creep test mostly close to the actual mechanical seal interface operating. Using the compression creep test results substitution in commonly viscoelastic model for compared accuracy rate. Selection of the generalized Kelvin five parameters model and the Brugers model, calculated the creep parameters of the composite model respectively.
5. Discussion on the marine mechanical seal operating characteristics, combined with basic and necessary assumption condition for simplifies the force on the end faces in sealing system. Finally, using the finite element method discussed contact characteristics in detail. The model is calculated by the actual mechanical seal structure; selected foam Nickel/PTFE composite material parameters used for the calculation of the simulation process analysis. The main content of the simulation is material contact stress in the operation process and strain distribution with the heat conduction rule.
By researching proven mesh nickel foam can reinforce material effectively improve the mechanical and technological properties of the composites, especially the wear resistance. However, along with the broaden engineering friction and wear applications, in the field of polymer matrix composites, explore the mesh material (three-dimensional morphology) packing as well as the synthesis of functional filler composite material, friction characteristics, mechanism of failure modes and other issues needs further explored.
引文
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