电解质-等离子加工技术中电解液作用的研究
|
摘要
电解质-等离子加工技术是建立在等离子化学及电化学的基础上,对金属材料进行表面处理,改善金属表面质量,达到抛光要求。该技术特别适用于形状复杂不易进行机械抛光的零件。同时该技术是一项“绿色”加工工艺,对环境无污染,相比其它抛光方法具有不可比拟的优势。本文主要通过系统试验,分析电解液的不同参数条件对电解质-等离子加工效果的影响。
对不锈钢材料进行工艺试验,探索电解质-等离子加工工艺,研究加工后材料的性能。以表面粗糙度值为试验指标进行电解液温度、浓度、流速参数的正交试验,利用极差分析得出不同参数对加工效果影响的主次顺序及最优组合。同时,从经济角度出发,以去除速率为试验指标的正交试验来验证试验结果,利用方差分析得出不同参数的显著性水平。从材料去除速度、表面粗糙度、耐腐蚀性等方面分析电解液不同参数对材料加工后表面性能的影响,根据加工效果对比,确定电解液的合理参数值,实现参数优化。
优化后,对加工样件与原始样件进行性能对比,结果表明:材料表面微观形貌得到了明显改善;表面粗糙度值Ra由0.133μm降到0.064μm;采用电化学方法考察耐蚀性的变化,极化曲线测试结果表明腐蚀电位正移,由-0.276V变为-0.224V,耐蚀性显著提高;表面光亮度由2级提高为5级,得到具有镜面光泽的表面;表层硬度HV由199.30变为189.24。从上述各方面的性能对比分析,验证电解液参数优化的合理性。
Electrolyte - Plasma processing technology, by means of plasma chemistry reaction and electrochemistry reaction, is a specific technology applied in the treatment of metal surfaces to improve the finishing quality of the metal for polishing. It is especially applied for polishing parts with complex shapes, making it difficult to mechanical polishing. Additionally and more importantly, Electrolyte - Plasma processing technology is environment-friendly. It has far more advantages than other polishing methods. This thesis, based on systematic tests, analyzes the performance of the Electrolyte - Plasma processing technology under different electrolytes parameters.
This thesis studies the Electrolyte - Plasma processing techniques by analysis of the performance of processed materials, utilizing stainless steel as the subject of analysis. The orthogonal experiment is respectively conducted on parameters of the electrolyte temperature, concentration and flow rate, with the value of surface roughness as the index. Then based on the method of range analysis , the order of the affecting degree of the three parameters on the processing effect is confirmed and the optimal parameters combination is determined. Taking economic effects into consideration, another orthogonal experiment, using the value of removal rate as the index, are respectively conducted on all three parameters either to confirm the results of the first orthogonal experiments. Then a significant level analysis of the three parameters is made by means of Analysis of Variance. Tests on the three parameter’s affecting on the result of the polishing process are respectively conducted, with the value of removal rate, surface roughness and corrosion resistance as the indexes. Through this series of tests, the most reasonable value of each parameter is determined by comparing respective processing performance. In this way, each parameter’s optimization is finally accomplished.
A comparison on metal’s surface performance before and after applying the optimum proposal shows: the material surface micro-topography is greatly improved; The surface roughness value (Ra) is reduced from 0.133μm to 0.064μm; The corrosion resistance is greatly improved according to a measurement test of Corrosion Electrochemistry and a Polarization curve test indicates that corrosion potential moved positively from -0.276V to -0.224V; The surface smoothness degree is increased from 2 to 5 and the processed material ends up with a surface with a mirror luster; The surface hardness value (HV) declines from 199.30 to 189.24. All these comparative analysis from various aspects of performances verify the reasonableness of the electrolyte parameter optimization.
对不锈钢材料进行工艺试验,探索电解质-等离子加工工艺,研究加工后材料的性能。以表面粗糙度值为试验指标进行电解液温度、浓度、流速参数的正交试验,利用极差分析得出不同参数对加工效果影响的主次顺序及最优组合。同时,从经济角度出发,以去除速率为试验指标的正交试验来验证试验结果,利用方差分析得出不同参数的显著性水平。从材料去除速度、表面粗糙度、耐腐蚀性等方面分析电解液不同参数对材料加工后表面性能的影响,根据加工效果对比,确定电解液的合理参数值,实现参数优化。
优化后,对加工样件与原始样件进行性能对比,结果表明:材料表面微观形貌得到了明显改善;表面粗糙度值Ra由0.133μm降到0.064μm;采用电化学方法考察耐蚀性的变化,极化曲线测试结果表明腐蚀电位正移,由-0.276V变为-0.224V,耐蚀性显著提高;表面光亮度由2级提高为5级,得到具有镜面光泽的表面;表层硬度HV由199.30变为189.24。从上述各方面的性能对比分析,验证电解液参数优化的合理性。
Electrolyte - Plasma processing technology, by means of plasma chemistry reaction and electrochemistry reaction, is a specific technology applied in the treatment of metal surfaces to improve the finishing quality of the metal for polishing. It is especially applied for polishing parts with complex shapes, making it difficult to mechanical polishing. Additionally and more importantly, Electrolyte - Plasma processing technology is environment-friendly. It has far more advantages than other polishing methods. This thesis, based on systematic tests, analyzes the performance of the Electrolyte - Plasma processing technology under different electrolytes parameters.
This thesis studies the Electrolyte - Plasma processing techniques by analysis of the performance of processed materials, utilizing stainless steel as the subject of analysis. The orthogonal experiment is respectively conducted on parameters of the electrolyte temperature, concentration and flow rate, with the value of surface roughness as the index. Then based on the method of range analysis , the order of the affecting degree of the three parameters on the processing effect is confirmed and the optimal parameters combination is determined. Taking economic effects into consideration, another orthogonal experiment, using the value of removal rate as the index, are respectively conducted on all three parameters either to confirm the results of the first orthogonal experiments. Then a significant level analysis of the three parameters is made by means of Analysis of Variance. Tests on the three parameter’s affecting on the result of the polishing process are respectively conducted, with the value of removal rate, surface roughness and corrosion resistance as the indexes. Through this series of tests, the most reasonable value of each parameter is determined by comparing respective processing performance. In this way, each parameter’s optimization is finally accomplished.
A comparison on metal’s surface performance before and after applying the optimum proposal shows: the material surface micro-topography is greatly improved; The surface roughness value (Ra) is reduced from 0.133μm to 0.064μm; The corrosion resistance is greatly improved according to a measurement test of Corrosion Electrochemistry and a Polarization curve test indicates that corrosion potential moved positively from -0.276V to -0.224V; The surface smoothness degree is increased from 2 to 5 and the processed material ends up with a surface with a mirror luster; The surface hardness value (HV) declines from 199.30 to 189.24. All these comparative analysis from various aspects of performances verify the reasonableness of the electrolyte parameter optimization.
引文
[1]许根慧,姜恩永,盛京.等离子体技术与应用[M].北京:化学工业出版社,2006:10-13.
[2]李定,陈银华,马锦秀.等离子体物理学[M].北京:高等教育出版社,2006:1-3.
[3]张谷令,敖玲,胡建芳.应用等离子体物理学[M].北京:首都师范大学出版社,2008:1-4.
[4]顾琅.等离子体科学发展概述[J].力学与实践,2010,32:102-105.
[5] Huang P C, Heberlein J, Pfender E. A Two-fluid Model of Turbulence for a Thermal Plasma Jet[J]. Plasma Chem Plasma Process,1995,15(1):25-46.
[6] Gao J. A Novel Technique for Wastewater Treatment by Contact Glow-discharge Electrolysis[J]. Pakistan Journal of Biological Sciences,2006,9(2):323-329.
[7]吴成康.我国等离子体工艺研究进展[J].物理,1999,27(7):388-393.
[8]严建华,戴尚莉,李晓东.气液两相滑动弧放电中自由基的光谱分析[J].光谱学与光谱分析,2008,28(8):1851-1855.
[9]赵化侨.等离子体化学与工艺[M].合肥:中国科学技术大学出版社,1993:107-118.
[10]孔凡杰.等离子点火器出口点火能量数值模拟分析[D].哈尔滨:哈尔滨工程大学,2007:1-2.
[11] Collares M P, Pfender E. Magnetic Probe Measurements in Plasma Spray Torches[C]. Proceedings of the 13th International Symposium on Plasma Chemistry,Beijing,China,1997(3):1466-1470.
[12] Brossard S, Munroe P R, Tran A T T. Study of the Effects of Surface Chemistry on Splat Formation for Plasma Sprayed NiCr onto Stainless Steel Substrates[J]. Surface & Coatings Technology,2010,204:1599-1607.
[13] Nunes A C, Bayless E O. Variable Polarty Plasma Arc Welding on the Space Shuttle External Tank[J]. Welding Journal,1984,9:27-35.
[14]李德元,赵文珍,董晓强.等离子技术在材料加工中的应用[M].北京:机械工业出版社,2005:25-30.
[15] Planche M P, Duan Z, Lagnoux O. Study of Arc Fluctuations with Different Plasmaspray Torch Configurations[C]. Proceedings of the 13th International Symposium on Plasma Chemistry,Beijing,China,1997(3):1460-1465.
[16]屈战民.浅谈不锈钢化学抛光剂的选择[J].电镀与涂饰,2003,22(4):46-47.
[17] Kaneko T, Baba K, Hatakeyama R. Gas-liquid Interfacial Plasmas Basic Properties and Applications to Nanomaterial Synthesis[J]. Plasma Phys Control Fusion,2009,51(12):4011-4018.
[18] Sun Y. Depth-profiling Electrochemical Measurements of Low Temperature Plasma Carburised 316L Stainless Steel in 1M HR2RSOR4RSolution[J]. Surface & Coatings Technology,2010,204:2789-2796.
[19]俞洁.辉光放电等离子体降解水体中的有机污染物[D].兰州:西北师范大学,2005:8-12.
[20]Электролитно-плазменноеполирование[DB/OL]. http://finishing.narod.ru/.
[21]СинькевичЮВ,ЯнковскийИН.ФазовыйСоставиМикроструктураЭлектроимпульсноПолированнойКоррозионно-стойкихСталей[J].БНТУ,2008,3(2):25-28.
[22]СемченкоНИ,КоролевАЮ.КоррозионноеПоведениеАустенитныхНержа-веющихСталейпослеЭлектролитно-плазменногоПолирования[J].БелорусскийНациональныйТехническийУниверситет,2008,4(2):10-13.
[23]马云,刘存海,王锦江.我国抛光处理材料的研究现状[J].新技术与新工艺,2003(12):48-50.
[24]王勇国,郭强,康爱军.不同组织类型对3Cr2MnNiMo钢抛光性能的影响[J].钢铁研究学报,2011,23(5):24-28.
[25] Jiang Z, Dou Y, Zhang Y. Effect of Chemical Polish Etching and Post Annealing on the Performance of Silicon Heterojunction Solar Cells[J]. Journal of Semiconductors,2009,3(8):1-4.
[26]方刚.不锈钢的电解抛光及钝化[J].电镀与精饰,2001,2(3):13-15.
[27]宋庆环.磁研磨法应用与模具型腔的光整加工[J].机械设计与制造,2009,2:248-250.
[28] Li X, Zhang X, Zhong F. The Development of Apparent Density Measuring Apparatus of Magnetic Lubricating Oil [J]. Key Engineering Materials,2008,815-819.
[29]翁慧燕,李振华.抛光的几种工艺对比[J].机械工程师,2010,3(6):28-32.
[30]马胜利,井晓天.电化学抛光对1Cr18Ni9Ti组织和性能的影响[J].材料保护,1998,31(8):26-28.
[31]Электролитно-плазменнаяПолировкаМеталлическихИзделий[DB/OL]. http://newblesk.narod.ru/.
[32]陈宁英.电浆抛光生产工艺[P].中国专利:101492833A,2009-07-29.
[33]ГоловкинаЕЯ.МетодЭлектроимпульсногоПолированияМеталлов[J].Машиностроение,1988,13:40-43.
[34]КузенковСЕ.ЛегированиеНагревиСтруктурнаяМодификацияСталивПроцессеМногофункциональнойАноднойОбработки[J].ВестиВысшихУчебныхЗаведенийЧерноземья,2010,1(19):57-63.
[35]КашаповРН.ИсследованиеПлазменно-электролитныхРазрядоввПроцессахОбработкиПоверхности[J]. Surface & Coatings Technology,2009,3(4):50-54.
[36]ХомутовОИ,ПлехановГВ,ТерентьевСД.ИсследованиеЭлектролитно-плазменногоПроцесса[DB/OL]. http://elib.altstu.ru:8080/Books/Files/2001-02/02/pap_02.html
[37]陈宁英.一机双挂等离子电浆抛光机构及其抛光系统.中国专利:101660193A,2010-03-03.
[38]贾铮,戴长松,陈玲.电化学测量方法[M].北京:化学工业出版社,2006,157-180.
[39]曹楚南.腐蚀电化学原理[M].北京:化学工业出版社,2008,99-176.
[40]曹楚南,张鉴清.电化学阻抗谱导论[M].北京:科学出版社,2002:24-36.
[41]李梁梁.镁合金生物陶瓷涂层制备及耐腐性能研究[D].哈尔滨:哈尔滨工业大学,2010:12-14.
[42]周德璧,崔莉莉,李琳. 304不锈钢在垃圾渗滤液中的腐蚀行为[J].腐蚀科学与防护技术,2009,21(1):48-51.
[43]董昕.正交试验方法在软件测试中的应用[J].北京化工大学学报,2007,34(1):130-132.
[44]刘卫国,田园.等离子体抛光对表面粗糙度的影响[J].西安工业大学学报,2010,30(2):108-112.
[45] Nie X, Meletis E I, Jiang J. Corrosion Properties and TEM Analysis of A1R2ROR3RCoatings Fabricated Using Plasma Electrolysis[J]. Surface Coatings Technology,2002,149:245-251.
[46]刘今起.不锈钢中性复合盐溶液电解抛光技术[J].航空精密制造技术,1993,29(2):22-23.
[47] Lopez V, Bartolome M J, Escudero. Comparison by SEM,TEM and EIS ofHydrothermally Sealed and Cold Sealed Aluminum Anodic Oxides[J]. Journal of The Electrochemical Society,2006,153:B75-B82.
[48]田弋纬,陈绍楷,苗壮.影响EDS分析准确性的因素探讨[J].西安文理学院学报,2010,13(3):83-86.
[49]刘峰,王琪,吴建华.等离子体钝化316L不锈钢抗点蚀性能研究[J].真空科学与技术学报,2010,30(4):434-437.
[50] Jiro O, Ken O, Asahiko I. Corrosion Resistance of Plasma-oxidized Stainless Steel[J]. Journal of The Electrochemical Society,2008,202:5595-5598.
[51]СинькевичЮВ.КомплексныйМетодкРазработкеТехнологическогоОбору-дованиядляЭлектроимпульсногоПолирования[J].БелорусскийНациональныйТехническийУниверситет,2009,3(2):45-48.
[52]倪国瑜.材料硬度计测量系统[D].上海:华东师范大学,2010:6-10.
[53]КомбаевКК,КылышкановМК,ЛопуховЮИ.ВлияниеЭлектролитно-плазменнойОбработкиСтали18ХН3МА-ШнаНоверхностнуюМикрострук-туруиТвердость[J]. Engineering & Technologies,2009,2(4):394-399.
[2]李定,陈银华,马锦秀.等离子体物理学[M].北京:高等教育出版社,2006:1-3.
[3]张谷令,敖玲,胡建芳.应用等离子体物理学[M].北京:首都师范大学出版社,2008:1-4.
[4]顾琅.等离子体科学发展概述[J].力学与实践,2010,32:102-105.
[5] Huang P C, Heberlein J, Pfender E. A Two-fluid Model of Turbulence for a Thermal Plasma Jet[J]. Plasma Chem Plasma Process,1995,15(1):25-46.
[6] Gao J. A Novel Technique for Wastewater Treatment by Contact Glow-discharge Electrolysis[J]. Pakistan Journal of Biological Sciences,2006,9(2):323-329.
[7]吴成康.我国等离子体工艺研究进展[J].物理,1999,27(7):388-393.
[8]严建华,戴尚莉,李晓东.气液两相滑动弧放电中自由基的光谱分析[J].光谱学与光谱分析,2008,28(8):1851-1855.
[9]赵化侨.等离子体化学与工艺[M].合肥:中国科学技术大学出版社,1993:107-118.
[10]孔凡杰.等离子点火器出口点火能量数值模拟分析[D].哈尔滨:哈尔滨工程大学,2007:1-2.
[11] Collares M P, Pfender E. Magnetic Probe Measurements in Plasma Spray Torches[C]. Proceedings of the 13th International Symposium on Plasma Chemistry,Beijing,China,1997(3):1466-1470.
[12] Brossard S, Munroe P R, Tran A T T. Study of the Effects of Surface Chemistry on Splat Formation for Plasma Sprayed NiCr onto Stainless Steel Substrates[J]. Surface & Coatings Technology,2010,204:1599-1607.
[13] Nunes A C, Bayless E O. Variable Polarty Plasma Arc Welding on the Space Shuttle External Tank[J]. Welding Journal,1984,9:27-35.
[14]李德元,赵文珍,董晓强.等离子技术在材料加工中的应用[M].北京:机械工业出版社,2005:25-30.
[15] Planche M P, Duan Z, Lagnoux O. Study of Arc Fluctuations with Different Plasmaspray Torch Configurations[C]. Proceedings of the 13th International Symposium on Plasma Chemistry,Beijing,China,1997(3):1460-1465.
[16]屈战民.浅谈不锈钢化学抛光剂的选择[J].电镀与涂饰,2003,22(4):46-47.
[17] Kaneko T, Baba K, Hatakeyama R. Gas-liquid Interfacial Plasmas Basic Properties and Applications to Nanomaterial Synthesis[J]. Plasma Phys Control Fusion,2009,51(12):4011-4018.
[18] Sun Y. Depth-profiling Electrochemical Measurements of Low Temperature Plasma Carburised 316L Stainless Steel in 1M HR2RSOR4RSolution[J]. Surface & Coatings Technology,2010,204:2789-2796.
[19]俞洁.辉光放电等离子体降解水体中的有机污染物[D].兰州:西北师范大学,2005:8-12.
[20]Электролитно-плазменноеполирование[DB/OL]. http://finishing.narod.ru/.
[21]СинькевичЮВ,ЯнковскийИН.ФазовыйСоставиМикроструктураЭлектроимпульсноПолированнойКоррозионно-стойкихСталей[J].БНТУ,2008,3(2):25-28.
[22]СемченкоНИ,КоролевАЮ.КоррозионноеПоведениеАустенитныхНержа-веющихСталейпослеЭлектролитно-плазменногоПолирования[J].БелорусскийНациональныйТехническийУниверситет,2008,4(2):10-13.
[23]马云,刘存海,王锦江.我国抛光处理材料的研究现状[J].新技术与新工艺,2003(12):48-50.
[24]王勇国,郭强,康爱军.不同组织类型对3Cr2MnNiMo钢抛光性能的影响[J].钢铁研究学报,2011,23(5):24-28.
[25] Jiang Z, Dou Y, Zhang Y. Effect of Chemical Polish Etching and Post Annealing on the Performance of Silicon Heterojunction Solar Cells[J]. Journal of Semiconductors,2009,3(8):1-4.
[26]方刚.不锈钢的电解抛光及钝化[J].电镀与精饰,2001,2(3):13-15.
[27]宋庆环.磁研磨法应用与模具型腔的光整加工[J].机械设计与制造,2009,2:248-250.
[28] Li X, Zhang X, Zhong F. The Development of Apparent Density Measuring Apparatus of Magnetic Lubricating Oil [J]. Key Engineering Materials,2008,815-819.
[29]翁慧燕,李振华.抛光的几种工艺对比[J].机械工程师,2010,3(6):28-32.
[30]马胜利,井晓天.电化学抛光对1Cr18Ni9Ti组织和性能的影响[J].材料保护,1998,31(8):26-28.
[31]Электролитно-плазменнаяПолировкаМеталлическихИзделий[DB/OL]. http://newblesk.narod.ru/.
[32]陈宁英.电浆抛光生产工艺[P].中国专利:101492833A,2009-07-29.
[33]ГоловкинаЕЯ.МетодЭлектроимпульсногоПолированияМеталлов[J].Машиностроение,1988,13:40-43.
[34]КузенковСЕ.ЛегированиеНагревиСтруктурнаяМодификацияСталивПроцессеМногофункциональнойАноднойОбработки[J].ВестиВысшихУчебныхЗаведенийЧерноземья,2010,1(19):57-63.
[35]КашаповРН.ИсследованиеПлазменно-электролитныхРазрядоввПроцессахОбработкиПоверхности[J]. Surface & Coatings Technology,2009,3(4):50-54.
[36]ХомутовОИ,ПлехановГВ,ТерентьевСД.ИсследованиеЭлектролитно-плазменногоПроцесса[DB/OL]. http://elib.altstu.ru:8080/Books/Files/2001-02/02/pap_02.html
[37]陈宁英.一机双挂等离子电浆抛光机构及其抛光系统.中国专利:101660193A,2010-03-03.
[38]贾铮,戴长松,陈玲.电化学测量方法[M].北京:化学工业出版社,2006,157-180.
[39]曹楚南.腐蚀电化学原理[M].北京:化学工业出版社,2008,99-176.
[40]曹楚南,张鉴清.电化学阻抗谱导论[M].北京:科学出版社,2002:24-36.
[41]李梁梁.镁合金生物陶瓷涂层制备及耐腐性能研究[D].哈尔滨:哈尔滨工业大学,2010:12-14.
[42]周德璧,崔莉莉,李琳. 304不锈钢在垃圾渗滤液中的腐蚀行为[J].腐蚀科学与防护技术,2009,21(1):48-51.
[43]董昕.正交试验方法在软件测试中的应用[J].北京化工大学学报,2007,34(1):130-132.
[44]刘卫国,田园.等离子体抛光对表面粗糙度的影响[J].西安工业大学学报,2010,30(2):108-112.
[45] Nie X, Meletis E I, Jiang J. Corrosion Properties and TEM Analysis of A1R2ROR3RCoatings Fabricated Using Plasma Electrolysis[J]. Surface Coatings Technology,2002,149:245-251.
[46]刘今起.不锈钢中性复合盐溶液电解抛光技术[J].航空精密制造技术,1993,29(2):22-23.
[47] Lopez V, Bartolome M J, Escudero. Comparison by SEM,TEM and EIS ofHydrothermally Sealed and Cold Sealed Aluminum Anodic Oxides[J]. Journal of The Electrochemical Society,2006,153:B75-B82.
[48]田弋纬,陈绍楷,苗壮.影响EDS分析准确性的因素探讨[J].西安文理学院学报,2010,13(3):83-86.
[49]刘峰,王琪,吴建华.等离子体钝化316L不锈钢抗点蚀性能研究[J].真空科学与技术学报,2010,30(4):434-437.
[50] Jiro O, Ken O, Asahiko I. Corrosion Resistance of Plasma-oxidized Stainless Steel[J]. Journal of The Electrochemical Society,2008,202:5595-5598.
[51]СинькевичЮВ.КомплексныйМетодкРазработкеТехнологическогоОбору-дованиядляЭлектроимпульсногоПолирования[J].БелорусскийНациональныйТехническийУниверситет,2009,3(2):45-48.
[52]倪国瑜.材料硬度计测量系统[D].上海:华东师范大学,2010:6-10.
[53]КомбаевКК,КылышкановМК,ЛопуховЮИ.ВлияниеЭлектролитно-плазменнойОбработкиСтали18ХН3МА-ШнаНоверхностнуюМикрострук-туруиТвердость[J]. Engineering & Technologies,2009,2(4):394-399.