镁合金高能表面强化研究
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摘要
材料的表面性能如疲劳、耐蚀、耐磨和热稳定性等决定了其服役环境和使用寿命,加强镁合金耐蚀耐磨性能的研究,对于推动镁合金更加广泛的应用并充分发挥其性能优势具有重要意义。本文通过高能撞击诱导表面自身纳米化和激光表面合金化两种工艺来达到改善镁合金材料表面性能的目的。
系统研究了高能撞击的工艺,优化出了适用于镁合金表面自身纳米化的工艺参数：N2和02压力为1.5 MPa,氮氧流量比为7：5,煤油流量为4 L/h,撞击颗粒粒径为Φ0.5mm、撞击距离在290-320mm范围内、处理时间在180-240s间,均能成功实现镁合金表面纳米化。
纳米化层的组织分析表明,撞击形变层变由严重塑性变形的表层、变形孪晶为主的亚表层及靠近基体轻微变形的过渡层,变形层呈明显的梯度变化特征。通过透射电镜(TEM/HRTEM)对微观精细组织结构的观察和分析,推演出了镁合金表面纳米化的内在细化机理,并建立了粗大晶粒在剧烈塑性形变条件下纳米晶粒形成模型。即：形变初始阶段以孪生为主,同时伴随着基面(0001)和棱柱面{1010}或{1120}的位错运动；形变中期以孪生和位错运动的协调/竞争为主,通过前期晶粒一定程度的细化和温度的升高,导致交滑移的产生,位错在后期的竞争中占据主导,进一步分割残余孪晶和微观条带状亚结构；随着畸变加剧、变形储能增加以及位错的增值、湮灭与重排,高能亚结构在足够的驱动力下发生了动态再结晶,最终形成了分布均匀、取向随机、晶界清晰的纳米晶粒。
纳米化层的行为研究表明,纳米化层为基体硬度的两倍左右,硬度纵向分布呈典型的梯度变化特征；纳米化层摩擦系数和磨损失重均显著减小,磨损机制为以粘着磨损和磨粒磨损为主,同时伴随着氧化磨损；在不同PH值的3.5%NaCl酸、碱、盐腐蚀介质中,纳米化层呈现耐蚀性明显恶化的特征；纳米化层热稳定的临界温度为330℃；纳米化层的微波加热扩散Al-Si合金时,随着微波加热温度的升高,合金化层厚度逐渐增加,纳米晶层的合金化层厚度为微米晶层的2-3倍。
研究了采用脉冲YAG激光进行镁合金激光表面合金化的工艺,得到了最佳工艺参数,即：脉宽为0.8 ms,频率为45Hz,光斑直径约为1.0 mm,电流220 A,扫描速度350mm/min。
Al-Nb/Al-TiB2和Al-(W, Ti)C系激光合金化的结果表明,合金化层中Al与Nb及基体成分Gd、Y等元素产生了原位反应,生成了高温硬质相Al2Gd、Al2Y、Al3Nb等金属间化合物,且在合金化过程中强化相TiB2和(W, Ti)C并未发生分解。表面宏观形貌显示,随着元素Al在合金化混合粉末中含量的减少,表面质量呈现出逐渐变差的趋势,出现了一定程度的结瘤现象。
激光合金化层的SEM观察发现,晶粒显著细化、分布均匀,整个横截面分为合金化层、过渡层和基体三部分；TEM观察显示,原位合成的新相如Al2Gd、Al2Y、A13Nb及强化相TiB2和(W, Ti)C等在合金化层中的分布弥散均匀,绝大多数形貌呈近球形,仅有小部分呈四边形块状,与基体结合部位较为圆润,且形成的大部分金属间化合物的尺寸在100 nm左右；通过进一步观察发现,粒度稍大的形貌并不是单个的化合物析出相,而是多个粒子的团聚,与基体之间具有良好的相容性。
激光合金化层的性能研究表明,合金化层的显微硬度提高达4-6倍；不同成分合金化层的干摩擦磨损性能得到明显提高,摩擦系数由基体的0.52左右降至0.25-0.35,磨损机理为粘着磨损、磨粒磨损和氧化磨损；成分配比为1：1左右时,激光表面合金化显著改善了镁合金材料在3.5%NaCl水溶液中的耐蚀性能。
In most cases, material failures occur on surfaces such as fretting fatigue, wear, corrosion and thermostability, etc. These failures are very sensitive to the structure and properties of the material surface. Optimization of the surface microstructure and properties is an effective approach to enhance the global behavior and service lifetime of materials. It has realistic significance for promoting wider application and giving full play to its unique performance advantages of magnesium alloys to strengthen the research on improving the wear and corrosion resistance. In this paper, the techniques of self-surface nanocrystallization induced by high-energy bombarding and laser alloying were used to achieve the purposes of improvement on surface properties of magnesium alloy.
The technology of high-energy bombarding was investigated systematically. The process parameters were optimized to applicable to self-surface nanocrystallization of a magnesium alloy as follows:the pressure of N2 and O2 is 1.5 MPa, nitrogen and oxygen flow ratio of 7:5, kerosene flow rate of 4 L/h, bombing particle diameter ofφ0.5 mm, impact distance range of 290～320 mm, handling time in the range of 180～240 s. The surface nanocrystallization on magnesium alloy can be obtained successfully using the above technological parameters.
Cross-sectional microstructure analysis of nano-layer revealed that the deformation layer presents gradient variation obviously, including the topmost surface layer of severe plastic deformation, deformation twins-based subsurface layer and a transition layer with slight deformation near the substrate. The inherent refinement mechanism of surface nanocrystallization on magnesium alloy was deduced through observation and analysis using transmission electron microscopy (TEM/HRTEM). Meanwhile, the grain refinement model of coarse grains converted into nano-grains was established under the condition of severe plastic deformation, i.e. the deformation model is dominated by mechanical twinning in the initial stage of magnesium alloy, and accompanied with the dislocation movement of basical plane (0001) and prismatic plane {10(?)0} or {11(?)0}. The coordination/competition between the deformation twinning and dislocation motion dominated the deformationprocess in the mid-stage of the severe plastic deformation. Subsequently, cross slip can be activated owing to a certain degree of grain refinement and temperature rising derived from high-energy bombarding, Dislocation movement dominates the competition in the later stage, and resulting in further fragmentation of the residual twins and micro-banded substructure. Then, the dynamic recrystallization occurred with sufficient driving force that coming from high-energy substructure with the increasing distortion, deformation storage increase, dislocation multiplication, annihilation and rearrangement. Eventually, the nano-grains formed with clear grain boundary, homogeneous distribution and random orientation.
The behaviors of nano-layer were studied systematically. The microhardness of the most top surface layer is about twice comparison with the substrate, and it is gradually decreasing with the increase of the depth from the surface. The friction coefficient and wear weight loss of nano-layer were reduced significantly, and adhesive wear and abrasive wear is the main wear mechanism, meanwhile, coupled with oxidation wear. It is found that the deterioration of corrosion resistance occurred for nano-layer in acid, alkali and salt 3.5% NaCl solution with different PH values. Thermal stability experiments show that the critical temperature of stabilized existence for nanocrystalline of magnesium alloy is 330℃. The vacuum microwave oven was used for experiments of diffusion alloying Al-Si alloy in magnesium alloy before and after the surface nanocrystallization treatment. It's worth noting that the diffusion alloying of magnesium alloy utilizing microwave heating has not been reported. The results showed that the thickness of alloyed layer increasing with the processing temperature increases, and the thickness of nano-treated alloying layer is more 2 to 3 times than that without nano-treatment.
Laser process of magnesium alloy by pulsed YAG laser surface alloying was investigated systematically. The optimized process parameters of laser surface alloying for Mg alloys are obtained as follows:pulse duration of 0.8 ms, frequency of 45 Hz, spot diameter of about 1.0 mm, current of 220 A and the scanning speed is 350 mm/min.
The results of laser surface alloying for Al-Nb/Al-TiB2 and Al-(W, Ti)C system showed that in situ reaction produced in the alloyed layer between the element Al and Nb, and the matrix elements Gd, Y, and generated a high-temperature hard-phase such as Al2Gd, Al2Y and Al3Nb intermetallic compounds. Furthermore, strengthening phase TiB2 and (W,Ti)C did not decompose by XRD diffraction analysis of the alloyed layer. Surface macro-morphology shows that there has been some degree of nodulation phenomenon on the quality of laser surface alloying with the content of alloying element Al tapering off in the mixed powders.
It is found that the entire cross-section is divided into three parts:alloyed layer, transition layer and matrix by SEM observation. The TEM observation shows that the grain refinement is significant and uniform distribution, furthermore, the new phases such as Al2Gd, Al2Y, Al3Nb, etc. of in situ synthesis and strengthening phase TiB2 and (W, Ti)C are uniformly dispersed in the alloyed layer, and most present nearly spherical shape, only a small part of that shows the quadrangle blocks like, and the size of most of intermetallic compounds is about 100 nm. It is worth noting that the morphology of larger size is not a single precipitates, but agglomeration of a number of fine particles by further observation.
The performance of laser alloyed layer shows that the hardness of alloyed layer is to improve up to 4-6 times compared with the substrate. The friction and wear performance of the alloyed layer with different alloying elements and the mass ratio can be improved under the condition of dry friction and wear significantly, and the friction coefficient changed from about 0.52 to 0.25～0.35. The main mechanism of wear for the alloyed layer is the adhesive wear, abrasive wear and oxidation wear. The corrosion resistance of magnesium alloy in 3.5% NaCl solution can be improved by laser surface alloying.
系统研究了高能撞击的工艺,优化出了适用于镁合金表面自身纳米化的工艺参数：N2和02压力为1.5 MPa,氮氧流量比为7：5,煤油流量为4 L/h,撞击颗粒粒径为Φ0.5mm、撞击距离在290-320mm范围内、处理时间在180-240s间,均能成功实现镁合金表面纳米化。
纳米化层的组织分析表明,撞击形变层变由严重塑性变形的表层、变形孪晶为主的亚表层及靠近基体轻微变形的过渡层,变形层呈明显的梯度变化特征。通过透射电镜(TEM/HRTEM)对微观精细组织结构的观察和分析,推演出了镁合金表面纳米化的内在细化机理,并建立了粗大晶粒在剧烈塑性形变条件下纳米晶粒形成模型。即：形变初始阶段以孪生为主,同时伴随着基面(0001)和棱柱面{1010}或{1120}的位错运动；形变中期以孪生和位错运动的协调/竞争为主,通过前期晶粒一定程度的细化和温度的升高,导致交滑移的产生,位错在后期的竞争中占据主导,进一步分割残余孪晶和微观条带状亚结构；随着畸变加剧、变形储能增加以及位错的增值、湮灭与重排,高能亚结构在足够的驱动力下发生了动态再结晶,最终形成了分布均匀、取向随机、晶界清晰的纳米晶粒。
纳米化层的行为研究表明,纳米化层为基体硬度的两倍左右,硬度纵向分布呈典型的梯度变化特征；纳米化层摩擦系数和磨损失重均显著减小,磨损机制为以粘着磨损和磨粒磨损为主,同时伴随着氧化磨损；在不同PH值的3.5%NaCl酸、碱、盐腐蚀介质中,纳米化层呈现耐蚀性明显恶化的特征；纳米化层热稳定的临界温度为330℃；纳米化层的微波加热扩散Al-Si合金时,随着微波加热温度的升高,合金化层厚度逐渐增加,纳米晶层的合金化层厚度为微米晶层的2-3倍。
研究了采用脉冲YAG激光进行镁合金激光表面合金化的工艺,得到了最佳工艺参数,即：脉宽为0.8 ms,频率为45Hz,光斑直径约为1.0 mm,电流220 A,扫描速度350mm/min。
Al-Nb/Al-TiB2和Al-(W, Ti)C系激光合金化的结果表明,合金化层中Al与Nb及基体成分Gd、Y等元素产生了原位反应,生成了高温硬质相Al2Gd、Al2Y、Al3Nb等金属间化合物,且在合金化过程中强化相TiB2和(W, Ti)C并未发生分解。表面宏观形貌显示,随着元素Al在合金化混合粉末中含量的减少,表面质量呈现出逐渐变差的趋势,出现了一定程度的结瘤现象。
激光合金化层的SEM观察发现,晶粒显著细化、分布均匀,整个横截面分为合金化层、过渡层和基体三部分；TEM观察显示,原位合成的新相如Al2Gd、Al2Y、A13Nb及强化相TiB2和(W, Ti)C等在合金化层中的分布弥散均匀,绝大多数形貌呈近球形,仅有小部分呈四边形块状,与基体结合部位较为圆润,且形成的大部分金属间化合物的尺寸在100 nm左右；通过进一步观察发现,粒度稍大的形貌并不是单个的化合物析出相,而是多个粒子的团聚,与基体之间具有良好的相容性。
激光合金化层的性能研究表明,合金化层的显微硬度提高达4-6倍；不同成分合金化层的干摩擦磨损性能得到明显提高,摩擦系数由基体的0.52左右降至0.25-0.35,磨损机理为粘着磨损、磨粒磨损和氧化磨损；成分配比为1：1左右时,激光表面合金化显著改善了镁合金材料在3.5%NaCl水溶液中的耐蚀性能。
In most cases, material failures occur on surfaces such as fretting fatigue, wear, corrosion and thermostability, etc. These failures are very sensitive to the structure and properties of the material surface. Optimization of the surface microstructure and properties is an effective approach to enhance the global behavior and service lifetime of materials. It has realistic significance for promoting wider application and giving full play to its unique performance advantages of magnesium alloys to strengthen the research on improving the wear and corrosion resistance. In this paper, the techniques of self-surface nanocrystallization induced by high-energy bombarding and laser alloying were used to achieve the purposes of improvement on surface properties of magnesium alloy.
The technology of high-energy bombarding was investigated systematically. The process parameters were optimized to applicable to self-surface nanocrystallization of a magnesium alloy as follows:the pressure of N2 and O2 is 1.5 MPa, nitrogen and oxygen flow ratio of 7:5, kerosene flow rate of 4 L/h, bombing particle diameter ofφ0.5 mm, impact distance range of 290～320 mm, handling time in the range of 180～240 s. The surface nanocrystallization on magnesium alloy can be obtained successfully using the above technological parameters.
Cross-sectional microstructure analysis of nano-layer revealed that the deformation layer presents gradient variation obviously, including the topmost surface layer of severe plastic deformation, deformation twins-based subsurface layer and a transition layer with slight deformation near the substrate. The inherent refinement mechanism of surface nanocrystallization on magnesium alloy was deduced through observation and analysis using transmission electron microscopy (TEM/HRTEM). Meanwhile, the grain refinement model of coarse grains converted into nano-grains was established under the condition of severe plastic deformation, i.e. the deformation model is dominated by mechanical twinning in the initial stage of magnesium alloy, and accompanied with the dislocation movement of basical plane (0001) and prismatic plane {10(?)0} or {11(?)0}. The coordination/competition between the deformation twinning and dislocation motion dominated the deformationprocess in the mid-stage of the severe plastic deformation. Subsequently, cross slip can be activated owing to a certain degree of grain refinement and temperature rising derived from high-energy bombarding, Dislocation movement dominates the competition in the later stage, and resulting in further fragmentation of the residual twins and micro-banded substructure. Then, the dynamic recrystallization occurred with sufficient driving force that coming from high-energy substructure with the increasing distortion, deformation storage increase, dislocation multiplication, annihilation and rearrangement. Eventually, the nano-grains formed with clear grain boundary, homogeneous distribution and random orientation.
The behaviors of nano-layer were studied systematically. The microhardness of the most top surface layer is about twice comparison with the substrate, and it is gradually decreasing with the increase of the depth from the surface. The friction coefficient and wear weight loss of nano-layer were reduced significantly, and adhesive wear and abrasive wear is the main wear mechanism, meanwhile, coupled with oxidation wear. It is found that the deterioration of corrosion resistance occurred for nano-layer in acid, alkali and salt 3.5% NaCl solution with different PH values. Thermal stability experiments show that the critical temperature of stabilized existence for nanocrystalline of magnesium alloy is 330℃. The vacuum microwave oven was used for experiments of diffusion alloying Al-Si alloy in magnesium alloy before and after the surface nanocrystallization treatment. It's worth noting that the diffusion alloying of magnesium alloy utilizing microwave heating has not been reported. The results showed that the thickness of alloyed layer increasing with the processing temperature increases, and the thickness of nano-treated alloying layer is more 2 to 3 times than that without nano-treatment.
Laser process of magnesium alloy by pulsed YAG laser surface alloying was investigated systematically. The optimized process parameters of laser surface alloying for Mg alloys are obtained as follows:pulse duration of 0.8 ms, frequency of 45 Hz, spot diameter of about 1.0 mm, current of 220 A and the scanning speed is 350 mm/min.
The results of laser surface alloying for Al-Nb/Al-TiB2 and Al-(W, Ti)C system showed that in situ reaction produced in the alloyed layer between the element Al and Nb, and the matrix elements Gd, Y, and generated a high-temperature hard-phase such as Al2Gd, Al2Y and Al3Nb intermetallic compounds. Furthermore, strengthening phase TiB2 and (W,Ti)C did not decompose by XRD diffraction analysis of the alloyed layer. Surface macro-morphology shows that there has been some degree of nodulation phenomenon on the quality of laser surface alloying with the content of alloying element Al tapering off in the mixed powders.
It is found that the entire cross-section is divided into three parts:alloyed layer, transition layer and matrix by SEM observation. The TEM observation shows that the grain refinement is significant and uniform distribution, furthermore, the new phases such as Al2Gd, Al2Y, Al3Nb, etc. of in situ synthesis and strengthening phase TiB2 and (W, Ti)C are uniformly dispersed in the alloyed layer, and most present nearly spherical shape, only a small part of that shows the quadrangle blocks like, and the size of most of intermetallic compounds is about 100 nm. It is worth noting that the morphology of larger size is not a single precipitates, but agglomeration of a number of fine particles by further observation.
The performance of laser alloyed layer shows that the hardness of alloyed layer is to improve up to 4-6 times compared with the substrate. The friction and wear performance of the alloyed layer with different alloying elements and the mass ratio can be improved under the condition of dry friction and wear significantly, and the friction coefficient changed from about 0.52 to 0.25～0.35. The main mechanism of wear for the alloyed layer is the adhesive wear, abrasive wear and oxidation wear. The corrosion resistance of magnesium alloy in 3.5% NaCl solution can be improved by laser surface alloying.
引文
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