微弧氧化在船用柴油机铝合金活塞上的应用
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摘要
铝合金活塞是内燃机中的重要部件,其工作条件极为复杂恶劣。微弧氧化技术可以在铝、镁、钛及其合金表面原位生长一层硬度高、耐磨、耐腐蚀和抗热冲击性能好的陶瓷膜层。本文利用微弧氧化技术在内燃机铝合金活塞表面原位生长一层致密的陶瓷层,大大提高了铝合金活塞的性能和使用寿命。
本试验采用纯方波窄脉冲直流电源,降低了微弧氧化的能耗。采用正交试验设计的方法,得到了最佳的电解液配方：Na2SiO3：8g／L：KOH：2～3g／L；Na2WO4：2g／L；H2O2：2ml／L；EDTA2Na：2g／L。因为本试验采用的电源易于实现恒压控制,所以本试验将电压也作为正交试验的一个因素,电压的优化结果为500～550V。在电解液配方和电压大小优化好的基础上对电源频率、占空比和微弧氧化时间进行了优化,优化结果是频率为600Hz,占空比为1／20,微弧氧化时间为50min。在优化好的电解液和电参数条件下得到了质地均匀致密,厚度在20μm以上的陶瓷膜层,微弧氧化电流密度保持在1A／dm2左右。
在优化好的电解液配方和电参数条件下,本试验在电解液中分别加入了二硫化钼微纳米颗粒和刚玉微纳米颗粒,得到了性能更为优越的微弧氧化膜层。
最后对微弧氧化膜层的性能进行了测试,其中包括微弧氧化膜层的绝热性能、抗热冲击性能和耐磨损性能。绝热性测试结果表明经微弧氧化处理的活塞试样在相同热源的条件下另一侧的温度要比未处理的活塞试样低84℃。经过十次600℃到10℃的热冲击试验,微弧氧化膜层没有出现任何裂纹和脱落的现象。在摩擦磨损试验中分别对四种不同方法处理的试样进行耐磨性能检测。试验结果表明经过微弧氧化处理的试样无论是在干摩擦还是油润滑的条件下试样与对摩材料的摩擦系数、试样的磨损失重等都要远优于未经处理的铝合金活塞试样。而电解液中加入二硫化钼微纳米颗粒和刚玉微纳米颗粒后得到的改性膜层试样的耐磨损性能得到了进一步的提高,表现出极为优越的耐磨损性能。
The aluminum piston is a component in the four-stroke marine diesel engine and its working conditions are severe and complex. Micro-arc oxidation can generate dense ceramic membrane on aluminum, magnesium, titanium and their alloys to improve surface quality including high hardness, wear resistance, corrosion resistance and thermal shock resistance etc. In this paper, micro-arc oxidation is used to fabricate a layer of dense ceramic coating which can greatly improve performance and service life of aluminum alloy pistons.
In this paper, the square-wave narrow pulses dc power is chosen to reduce the consumption of micro-arc oxidation. Adopting the orthogonal experiment method, the optimal formula of electrolyte are 8g/L forNa2Si03,2-3g/L for KOH,2g/L for Na2WO4, 2ml/L for H2O2 and2g/L for EDTA2Na. Because the power supply used in this test are easy to be realized the constant voltage control, the voltage is chosen as a factor of orthogonal experiment design. The optimal result for voltage is 500V～550V. Based on the optimal electrolyte formula and voltage, the optimal result is that frequency is 600Hz, duty cycle 1/20 and oxidation time 50 min. Under the optimal conditions, dense ceramic coating is got with its thickness which is more than 20μm and micro-arc oxidation current density remains at the level of 1 A/dm2.
Superior ceramic coatings are got through adding nano-particles of molybdenum disulfide and alumina into the optimized electrolyte.
The result of insulation test shows that, after micro-arc oxidation treatment, the sample of piston possesses good insulating properties. After thermal shock tests from 600℃to 10℃for ten times, micro-arc oxidation film remains intact without any cracks and shedding. The results of friction and wear test show that the samples treated by micro-arc oxidation have better properties in friction coefficient and weight loss than the untreated ones under the conditions of both dry friction and oil lubrication. The samples which are obtained in the electrolytes that are added nano-particles of molybdenum disulfide and alumina have much more excellent anti-wear properties than other samples.
本试验采用纯方波窄脉冲直流电源,降低了微弧氧化的能耗。采用正交试验设计的方法,得到了最佳的电解液配方：Na2SiO3：8g／L：KOH：2～3g／L；Na2WO4：2g／L；H2O2：2ml／L；EDTA2Na：2g／L。因为本试验采用的电源易于实现恒压控制,所以本试验将电压也作为正交试验的一个因素,电压的优化结果为500～550V。在电解液配方和电压大小优化好的基础上对电源频率、占空比和微弧氧化时间进行了优化,优化结果是频率为600Hz,占空比为1／20,微弧氧化时间为50min。在优化好的电解液和电参数条件下得到了质地均匀致密,厚度在20μm以上的陶瓷膜层,微弧氧化电流密度保持在1A／dm2左右。
在优化好的电解液配方和电参数条件下,本试验在电解液中分别加入了二硫化钼微纳米颗粒和刚玉微纳米颗粒,得到了性能更为优越的微弧氧化膜层。
最后对微弧氧化膜层的性能进行了测试,其中包括微弧氧化膜层的绝热性能、抗热冲击性能和耐磨损性能。绝热性测试结果表明经微弧氧化处理的活塞试样在相同热源的条件下另一侧的温度要比未处理的活塞试样低84℃。经过十次600℃到10℃的热冲击试验,微弧氧化膜层没有出现任何裂纹和脱落的现象。在摩擦磨损试验中分别对四种不同方法处理的试样进行耐磨性能检测。试验结果表明经过微弧氧化处理的试样无论是在干摩擦还是油润滑的条件下试样与对摩材料的摩擦系数、试样的磨损失重等都要远优于未经处理的铝合金活塞试样。而电解液中加入二硫化钼微纳米颗粒和刚玉微纳米颗粒后得到的改性膜层试样的耐磨损性能得到了进一步的提高,表现出极为优越的耐磨损性能。
The aluminum piston is a component in the four-stroke marine diesel engine and its working conditions are severe and complex. Micro-arc oxidation can generate dense ceramic membrane on aluminum, magnesium, titanium and their alloys to improve surface quality including high hardness, wear resistance, corrosion resistance and thermal shock resistance etc. In this paper, micro-arc oxidation is used to fabricate a layer of dense ceramic coating which can greatly improve performance and service life of aluminum alloy pistons.
In this paper, the square-wave narrow pulses dc power is chosen to reduce the consumption of micro-arc oxidation. Adopting the orthogonal experiment method, the optimal formula of electrolyte are 8g/L forNa2Si03,2-3g/L for KOH,2g/L for Na2WO4, 2ml/L for H2O2 and2g/L for EDTA2Na. Because the power supply used in this test are easy to be realized the constant voltage control, the voltage is chosen as a factor of orthogonal experiment design. The optimal result for voltage is 500V～550V. Based on the optimal electrolyte formula and voltage, the optimal result is that frequency is 600Hz, duty cycle 1/20 and oxidation time 50 min. Under the optimal conditions, dense ceramic coating is got with its thickness which is more than 20μm and micro-arc oxidation current density remains at the level of 1 A/dm2.
Superior ceramic coatings are got through adding nano-particles of molybdenum disulfide and alumina into the optimized electrolyte.
The result of insulation test shows that, after micro-arc oxidation treatment, the sample of piston possesses good insulating properties. After thermal shock tests from 600℃to 10℃for ten times, micro-arc oxidation film remains intact without any cracks and shedding. The results of friction and wear test show that the samples treated by micro-arc oxidation have better properties in friction coefficient and weight loss than the untreated ones under the conditions of both dry friction and oil lubrication. The samples which are obtained in the electrolytes that are added nano-particles of molybdenum disulfide and alumina have much more excellent anti-wear properties than other samples.
引文
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[2]吕彩琴,苏铁熊,柴油机的热及惯性力耦合研究[J].柴油机设计与制造,2008,(02)：2-4.
[3]吕彩琴,苏铁熊.柴油机在复杂载荷条件下的强度研究[J].车辆与动力技术,2009,(02)：1-4.
[4]沈季胜.活塞热冲击与随机传热过程的研究[D].浙江大学,2002：45-50.
[5]魏同波,田军.LY12铝合金微弧氧化陶瓷层的结构和性能[J].材料研究学报,2004,(02)：2-3.
[6]H.M. Nykyforchyn M.D. Klapkiv and V.M. Posuvailo. Properties of synthesised oxide-ceramic coatings in electrolyte plasma on aluminium alloys.Surface and Coatings Technology,1998, 100-101:219-221.
[7]刘彩文,吴士军.铝合金表面微弧氧化技术的研究进展[J].内蒙古化工,2006,(06).2-4.
[8]张萍.铝合金高硬度阳极氧化膜层的制备与研究[D].西华大学,2008：9-13.
[9]郭鹤同,王为.铝阳极氧化的回顾与展望[J].材料保护,2000,(01).1-3.
[10]崔昌军,彭乔.铝及铝合金的阳极氧化研究综述[J].全面腐蚀控制,2002,(06)
[11]Wong C M, Moji Y, Method for anodizing aluminum.US489427.1990:6-16.
[12]http://baike.baidu.com/view/1318251.htm?fr=ala0_1
[13]丁毅.微弧氧化技术替代电镀硬铬应用研究[D].长安大学,2006：3-8.
[14]李家柱,林安.取代重污染六价铬电镀的技术及应用[J].电镀与涂饰,2004,(04).2-5.
[15]刘稳善,张天明.活塞表面等离子喷涂强化及耐磨性能研究[J].柴油机,2004,(05).3-4.
[16]邹莉.等离子喷涂技术及应用[J].昆明冶金高等专科学校学报,2005,(05).1-2.
[17]辛铁柱.铝合金表面微弧氧化陶瓷膜生成及机理研究[D].哈尔滨工业大学,2006：9-18.
[18]刘杰.低能耗铝合金微弧氧化技术研究[D].大连海事大学,2008：4-12.
[19]Yerokhin A L, Lyubimov V V, Ashitkov R V. Phase formation in ceramic coatings during plasma electrolytic oxidation of aluminum alloys.Ceramics International,1998,24 (1):1-6.
[20]张群.微弧氧化技术在铝制缸体内表面耐磨处理中的应用[D].西安理工大学,2006：6-11.
[21]http://baike.baidu.com/view/1277.htm?fr=ala0_1_1
[22]侯正全.ZL201铸造铝合金微弧氧化工艺研究[D].上海交通大学,2007：10-15.
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