目的 利用射频感应耦合等离子体喷涂（RF-ICPS）技术在第一壁材料钨（W）表面制备碳化硼（B4C）涂层,研究等离子体工作气体中掺氦（He）对涂层质量的影响。方法 采用实验表征与数值模拟相结合的方法,通过在工作气体中掺入不同体积分数的He,制备B4C涂层,表征涂层表面形貌和组成变化。采用Ansys Fluent模拟软件,建立三维射频等离子体与B4C颗粒之间的有限元模型,探究在等离子体中加入He,通过调控等离子体属性参数,进而影响涂层制备的内在机理。结果 随着等离子体工作气体中He的体积分数的提升,可明显降低涂层的孔隙率,当He的体积分数升高到7.2%时,孔隙率降至1.1%,且涂层的主要组成未发生变化。模拟结果显示,当He的体积分数从0%升高到7.2%时,等离子体焓值提高了38%,同时颗粒加热熔融效果明显提升;当He的体积分数升高到7.2%时,B4C颗粒温度达到2 800 K以上的占65.5%。结论 在等离子体工作气体中加入 He,不仅具有提高等离子体热导率的作用,还可以提高等离子体的焓值,促进飞行B4C颗粒在等离子体中的加热效果,从而提升涂层的致密度。
Abstract
Radio frequency inductive coupled plasma spraying (RF-ICPS) is one of the most advanced plasma spraying methods in the world, and helium (He) is an effective method to improve the coating properties. The work aims to prepare boron carbide (B4C) coatings on the surface of first-wall materials (W), and systematically investigate the effects of helium (He) volume fraction on the surface morphology and composition of the coatings through experimental characterization and numerical simulation. High-performance first-wall materials are particularly important for the operation of fusion reactors. In this study, B4C coatings were prepared by RF-ICPS under controlled atmosphere at atmospheric pressure, and the effects of He volume fraction in the plasma working gas on the surface morphology and composition of the coatings were investigated by scanning electron microscopy (SEM) and X-ray diffraction (XRD), with special attention paid to the effects on the porosity. At the same time, the interaction between the plasma and the particles during the spraying process was analyzed with three-dimensional numerical simulation, which revealed the intrinsic mechanism of the He volume fraction affecting the coating preparation through the change of the plasma property parameters in the experimental process. The experimental results showed that the particles could only be partially melted before He was added, and the raw material powders were all aggregated particles, most of which reached the substrate and could not spread well, and the coating porosity was as high as 13.2%. When the He volume fraction increased to 7.2%, the surface of the coating was flat, most of the particles could be melted, and a large number of particles were involved in the slat formation process, and the coating porosity was reduced to 1.1%. Meanwhile, the XRD results showed that He improved the heating effect of the particles and accelerated the evaporation of C and SiC in the pristine powder, which effectively removed the impurity components and enhanced the purity of the coating. The simulation results showed that the proportion of He in the plasma working gas not only had the effect of increasing the thermal conductivity of the plasma in the preparation of B4C coatings by RF-ICPS, but also increased the enthalpy of the plasma. When the He volume fraction increased from 0% to 7.2%, the maximum value of enthalpy increased from 7.2 MJ/kg to 10 MJ/kg, which was 38% higher relative to that before He was added. At the same time, the heating and melting effect of the particles was obviously improved, and the temperature of the particles reached over 2 800 K in 65.5% of the cases when the He volume fraction increased to 7.2%, whereas only 20% of the particles had a temperature over 2 800 K before the addition of He. The simulation and experimental results further confirm that the addition of He to the RF plasma significantly improves the melting effect of B4C particles in the plasma, which contributes to the formation of a denser, low porosity coating structure. These studies serve as an important guide and reference for the optimization of process parameters for the preparation of high-quality B4C coatings by inductively coupled plasma.
关键词
射频感应耦合等离子体 /
碳化硼涂层 /
He /
数值模拟
Key words
radio frequency inductive coupled plasma /
boron carbide coating /
He /
numerical simulation
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基金
国家自然科学基金（11875039）;山西省回国留学人员科研教研资助项目（2023-033）;山西省基础研究计划（202303021221071）;安徽省重大产业创新计划（AHZDCYCX-LSDT2023-01）
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