金属表面纳米晶化方法及性能研究
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摘要
在金属表面获得纳米晶层可提高材料的性能,是近年来纳米材料领域的研究热点。本文克服现有强烈塑性变形致纳米晶化方法的局限性,开发成功两种可实际应用的表面纳米晶层制备方法,对所得纳米晶组织进行分析表征和性能研究。
主要研究内容及成果如下：
(1)将现有基于振动原理消除焊接残余应力的超声冲击处理方法引入表面工程领域,开发了超声冲击处理诱导金属表层纳米晶化技术,成功地在35钢表面30μm-100μm厚度范围内制备出晶粒尺度为10nm-35nm的纳米晶结构。
(2)开发出制备金属纳米晶表层的法向脉动旋压方法和深冷处理技术。在-196℃深冷条件下,实现了显微组织主要为片状纳米孪晶或等轴纳米晶的铜纳米晶层的可控制备。
(3)采用多种分析测试方法,对不同制备工艺条件下获得的纳米晶结构进行表征,研究了制备工艺参数对金属表层显微组织结构的影响规律。表层显微组织结构演变机理分析结果表明,超声冲击处理诱发的35钢表层的塑性变形为以位错滑移为主的变形方式,而深冷法向脉动旋压处理导致的铜表层的塑性变形方式则以变形孪生为主。
(4)进行了超声冲击纳米晶化35钢的硬度分布、摩擦磨损和疲劳性能试验研究,并对改善堆焊层残余应力分布的效果进行了测试评价。结果表明,超声冲击表面纳米晶化处理可显著提高塑性变形层的硬度,降低表面摩擦系数,提高抗磨损性能和高周疲劳强度。
(5)在国内外首次开展了强烈塑性变形致金属纳米晶表面的润湿性及冷凝传热特性试验研究,采用可视化动态显微分析方法,定量表征了滴状冷凝液滴的动力学行为和参数。结果表明,纳米晶铜表面的冷凝传热系数为原始铜表面的2-3倍,冷凝传热得到显著强化,其机理为纳米晶铜表面的接触角比原始铜表面增大了2倍左右,纳米晶化显著降低了表面的润湿性,导致蒸汽冷凝的模式由原始铜表面的膜状冷凝转变为滴状冷凝或以滴状冷凝占主导的模式。
(6)采用自行设计、建立的实验系统,首次对纳米晶铜表面的池沸腾传热特性进行试验研究,应用高速摄影方法观测了纳米晶化前、后铜表面气泡生长与脱离的全过程,对比分析了气泡的形貌、生长周期和脱离频率,揭示了纳米晶表面强化沸腾传热的机理。研究结果表明,经纳米晶化处理,铜表面的起始沸腾过热度由原始铜表面的10℃左右降低到仅为5-6℃,纳米晶表面的热通量明显增高,沸腾传热系数最高可达原始铜表面的1.6倍。纳米晶表面的气泡脱离直径较小,生长周期缩短为原来的66%,是其具有显著强化沸腾传热效果的主要机理。
Obtaining nanocrystalline layers in the surface of metallic materials have attracted great attention of researchers over the past decades. Two kinds of deformation processes which can be applied in the industry were successively developed, which can obtain the nanocrystalline layers in the surface of various metallic materials to overcome the limitations of existing severe plastic deformation methods. Microstructures and properties of the obtained surface layers were investigated in this dissertation.
The main research and conclusions are as follows:
(1) Ultrasonic impact peening (UIP) process, which was conventionally used to eliminate welding residual stress, was firstly introduced to induce surface nanocrystallization of metallic materials. Nanocrystal layers with the grain size ranging from 10 to 35 nm,30-100μm thick, on the surface of 35 steel were obtained by ultrasonic impact peening process.
(2) A novel normal pulse spinning (NPS) method and cryogenic treatment technique were developed for synthesizing a nanostructured surface layer on metallic materials. Controllable microstructures of lamellar nano-twins or equiaxed nanocrystalline copper were produced by NPS process at the temperature of-196℃.
(3) Microstructure features of various sections in the nanocrystalline surface layer synthesized by UIP and NPS processes were systematically characterized to investigate the grain refinement mechanism. The analyses of microstructural evolution revealed that plastic deformation of 35 steel surface layers by UIP process were induced by dislocation sliding, while the deformation twinning was the main carrier in copper during NPS.
(4) Distribution of microhardness and properties of fatigue, friction and wear were experimentally investigated for nanostructured surface layer on 35 steel induced by UIP method. The results showed that surface nanocrystallization can increase the hardness of the plastic deformation layer and fatigue strength, decrease the surface friction coefficient, and improve the anti-wear property.
(5) Experimental investigation on wettability and condensation heat transfer characteristics from nanocrystalline metallic surfaces, which were produced via severe plastic deformation, was conducted. To our knowledge, this has been the first one ever reported. The dynamics behavior and parameters of condensed droplets in the dropwise condensation were quantitatively characterized by the method combining the motional visualization and microscopic analysis. The results showed that the condensation heat transfer coefficient from the nanocrystalline copper surface was 2-3 times that from the untreated copper surface, which remarkably enhances condensation heat transfer. This is because that the contact angle of the nanocrystalline copper surface is two times higher than that of the untreated copper surface. The nanocrystallization of the copper surface significantly decreased the surface wettability, and consequently, the vapor condensation mode transferred from the filmwise mode to the dropwise or dropwise-dominant mode.
(6) With the test facility designed and established by our lab, the experiment of pool boiling heat transfer characteristics from the nanocrystalline copper surface was carried out for the first time. The entire process of bubble growth and departure from the copper surfaces before and after nanocrystallization was observed and recorded with the high-speed visualization method. The bubble morphology, growth period and departure frequency from the two types of surfaces were analyzed and compared to reveal the boiling heat transfer enhancing mechanism of the nanocrystalline surface. It was shown by results that the incipient wall superheat for nucleate boiling from the copper surface was decreased from around 10℃to 5～6℃, after the nanocrystallization of the surface. At a given wall superheat, the nanocrystallne surface could transfer much higher heat flux, and therefore yielded a boiling heat transfer coefficient 1.6 times higher than the untreated surface. The main reason for the enhancement of boiling heat transfer is that bubles on the heated nanocrystalline surface have smaller smaller departure diameter and shorter growth period compared with that on the untreated surface.
主要研究内容及成果如下：
(1)将现有基于振动原理消除焊接残余应力的超声冲击处理方法引入表面工程领域,开发了超声冲击处理诱导金属表层纳米晶化技术,成功地在35钢表面30μm-100μm厚度范围内制备出晶粒尺度为10nm-35nm的纳米晶结构。
(2)开发出制备金属纳米晶表层的法向脉动旋压方法和深冷处理技术。在-196℃深冷条件下,实现了显微组织主要为片状纳米孪晶或等轴纳米晶的铜纳米晶层的可控制备。
(3)采用多种分析测试方法,对不同制备工艺条件下获得的纳米晶结构进行表征,研究了制备工艺参数对金属表层显微组织结构的影响规律。表层显微组织结构演变机理分析结果表明,超声冲击处理诱发的35钢表层的塑性变形为以位错滑移为主的变形方式,而深冷法向脉动旋压处理导致的铜表层的塑性变形方式则以变形孪生为主。
(4)进行了超声冲击纳米晶化35钢的硬度分布、摩擦磨损和疲劳性能试验研究,并对改善堆焊层残余应力分布的效果进行了测试评价。结果表明,超声冲击表面纳米晶化处理可显著提高塑性变形层的硬度,降低表面摩擦系数,提高抗磨损性能和高周疲劳强度。
(5)在国内外首次开展了强烈塑性变形致金属纳米晶表面的润湿性及冷凝传热特性试验研究,采用可视化动态显微分析方法,定量表征了滴状冷凝液滴的动力学行为和参数。结果表明,纳米晶铜表面的冷凝传热系数为原始铜表面的2-3倍,冷凝传热得到显著强化,其机理为纳米晶铜表面的接触角比原始铜表面增大了2倍左右,纳米晶化显著降低了表面的润湿性,导致蒸汽冷凝的模式由原始铜表面的膜状冷凝转变为滴状冷凝或以滴状冷凝占主导的模式。
(6)采用自行设计、建立的实验系统,首次对纳米晶铜表面的池沸腾传热特性进行试验研究,应用高速摄影方法观测了纳米晶化前、后铜表面气泡生长与脱离的全过程,对比分析了气泡的形貌、生长周期和脱离频率,揭示了纳米晶表面强化沸腾传热的机理。研究结果表明,经纳米晶化处理,铜表面的起始沸腾过热度由原始铜表面的10℃左右降低到仅为5-6℃,纳米晶表面的热通量明显增高,沸腾传热系数最高可达原始铜表面的1.6倍。纳米晶表面的气泡脱离直径较小,生长周期缩短为原来的66%,是其具有显著强化沸腾传热效果的主要机理。
Obtaining nanocrystalline layers in the surface of metallic materials have attracted great attention of researchers over the past decades. Two kinds of deformation processes which can be applied in the industry were successively developed, which can obtain the nanocrystalline layers in the surface of various metallic materials to overcome the limitations of existing severe plastic deformation methods. Microstructures and properties of the obtained surface layers were investigated in this dissertation.
The main research and conclusions are as follows:
(1) Ultrasonic impact peening (UIP) process, which was conventionally used to eliminate welding residual stress, was firstly introduced to induce surface nanocrystallization of metallic materials. Nanocrystal layers with the grain size ranging from 10 to 35 nm,30-100μm thick, on the surface of 35 steel were obtained by ultrasonic impact peening process.
(2) A novel normal pulse spinning (NPS) method and cryogenic treatment technique were developed for synthesizing a nanostructured surface layer on metallic materials. Controllable microstructures of lamellar nano-twins or equiaxed nanocrystalline copper were produced by NPS process at the temperature of-196℃.
(3) Microstructure features of various sections in the nanocrystalline surface layer synthesized by UIP and NPS processes were systematically characterized to investigate the grain refinement mechanism. The analyses of microstructural evolution revealed that plastic deformation of 35 steel surface layers by UIP process were induced by dislocation sliding, while the deformation twinning was the main carrier in copper during NPS.
(4) Distribution of microhardness and properties of fatigue, friction and wear were experimentally investigated for nanostructured surface layer on 35 steel induced by UIP method. The results showed that surface nanocrystallization can increase the hardness of the plastic deformation layer and fatigue strength, decrease the surface friction coefficient, and improve the anti-wear property.
(5) Experimental investigation on wettability and condensation heat transfer characteristics from nanocrystalline metallic surfaces, which were produced via severe plastic deformation, was conducted. To our knowledge, this has been the first one ever reported. The dynamics behavior and parameters of condensed droplets in the dropwise condensation were quantitatively characterized by the method combining the motional visualization and microscopic analysis. The results showed that the condensation heat transfer coefficient from the nanocrystalline copper surface was 2-3 times that from the untreated copper surface, which remarkably enhances condensation heat transfer. This is because that the contact angle of the nanocrystalline copper surface is two times higher than that of the untreated copper surface. The nanocrystallization of the copper surface significantly decreased the surface wettability, and consequently, the vapor condensation mode transferred from the filmwise mode to the dropwise or dropwise-dominant mode.
(6) With the test facility designed and established by our lab, the experiment of pool boiling heat transfer characteristics from the nanocrystalline copper surface was carried out for the first time. The entire process of bubble growth and departure from the copper surfaces before and after nanocrystallization was observed and recorded with the high-speed visualization method. The bubble morphology, growth period and departure frequency from the two types of surfaces were analyzed and compared to reveal the boiling heat transfer enhancing mechanism of the nanocrystalline surface. It was shown by results that the incipient wall superheat for nucleate boiling from the copper surface was decreased from around 10℃to 5～6℃, after the nanocrystallization of the surface. At a given wall superheat, the nanocrystallne surface could transfer much higher heat flux, and therefore yielded a boiling heat transfer coefficient 1.6 times higher than the untreated surface. The main reason for the enhancement of boiling heat transfer is that bubles on the heated nanocrystalline surface have smaller smaller departure diameter and shorter growth period compared with that on the untreated surface.
引文
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