目的 利用大气等离子喷涂制备一种具有优异耐微动磨损性能的CuNi涂层,以替代传统CuNiIn涂层。方法 通过粉末B合金化设计,利用B元素在喷涂过程中具有清除CuNi熔滴飞行氧化的作用,采用大气等离子喷涂在不锈钢基体表面制备CuNi4B涂层。通过SEM、EDS等表征手段,系统研究B合金化对CuNi涂层微观组织结构的影响,并结合硬度测试和微动磨损试验,检验B合金化对CuNi涂层抗微动磨损性能的提升效果。结果 添加B元素能够显著抑制大气等离子喷涂过程中CuNi熔滴的飞行氧化,减少涂层中的氧化物夹杂,从而形成致密且粒子间结合良好的CuNi涂层。涂层中残余的B元素通过提高硬度,提升了涂层的抗黏着磨损能力。与CuNiIn涂层和CuNi块材相比,CuNi4B涂层的平均摩擦因数为0.65,相较于CuNiIn涂层,降低了34%。经过10 000次微动磨损循环后,CuNiIn涂层的磨损量达到6 μm3,磨损机制为黏着磨损、氧化磨损和粒子间疲劳脱层;CuNi4B涂层的磨损量仅为0.83 μm3,主要表现为轻度黏着磨损,同时伴有氧化磨损。CuNi4B涂层在磨损循环次数为10 000时的磨损量仅为传统CuNiIn涂层的1/6。结论 B元素的掺入显著提升了CuNi涂层的抗微动磨损性能,可为CuNi4B涂层替代传统CuNiIn涂层提供理论依据。
Abstract
Atmospheric plasma-sprayed (APS) CuNiIn coatings have been widely used for fretting wear protection in aerospace and automotive components due to their excellent anti-fretting performance. However, the toxicity of indium (In) and its limited supply have prompted the exploration of alternative materials. In addition, the fretting wear performance of the APS CuNiIn coatings is compromised by the weak inter-splats bonding quality, which can be attributed to high content of oxide inclusions resulting from the in-flight oxidation of metal droplets during the spray process. In this study, APS CuNi4B coatings were investigated as a potential replacement for conventional CuNiIn coatings in fretting wear applications. It was expected that the incorporation of B into CuNi powder would suppress the in-flight oxidation of CuNi molten droplets during APS, thereby improving the bonding quality of the deposited CuNi4B coatings. The effect of B addition on the microstructure of the CuNi coatings was analyzed through SEM. Fretting wear tests were performed to assess the effect of B addition on the fretting wear resistance of coatings. Research findings demonstrate that the addition of B effectively suppresses the in-flight oxidation of CuNi droplets during atmospheric plasma spraying, enabling the deposition of CuNi4B coatings with dense microstructure and excellent intersplat bonding quality. The residual boron element in the CuNi coating can significantly enhance its microhardness. The traditional atmospheric plasma-sprayed CuNiIn coating exhibits a microhardness of 171HV0.2, whereas the CuNi4B coating demonstrates a markedly higher hardness of 512HV0.2. Fretting wear test results show that the CuNiB coating exhibits a friction coefficient evolution trend similar to that of the CuNiIn coating throughout the cyclic loading process. However, the friction coefficient of the CuNi4B coating is significantly lower than that of both the CuNiIn coating and the bulk CuNi material. The average friction coefficient of the CuNi4B coating is approximately 0.65, representing a 34% reduction relative to the CuNiIn coating. After 10 000 fretting cycles, the wear volume of the CuNiIn coating reaches 6 μm3, with wear mechanisms characterized by adhesive wear, oxidative wear, and inter-splat fatigue delamination. In contrast, the CuNi4B coating exhibits a significantly reduced wear volume of only 0.83 μm3, dominated by mild adhesive wear accompanied by limited oxidative wear. The volume loss of the CuNi4B coating at 10 000 fretting wear cycles is approximately one-sixth of that of the conventional APS CuNiIn coating. The improvement in the fretting wear resistance of the CuNi4B coating is primarily attributed to the effective suppression of in-flight oxidation during atmospheric plasma spraying by boron addition, which results in a dense coating microstructure characterized by low oxygen content and low porosity. During fretting wear, this dense structure significantly reduces material loss rates. Furthermore, the residual borides within the coating substantially enhance its microhardness, effectively mitigating adhesive phenomena in the initial wear stage. Meanwhile, the relatively high microhardness of the CuNi4B coating can also suppress the spallation behavior of the surface material under stress, further reducing material loss. These results demonstrate the feasibility of preparing Indium-free coatings with excellent fretting wear resistance by APS.
关键词
CuNiIn涂层 /
CuNi4B涂层 /
大气等离子喷涂 /
硬度 /
层间结合 /
微动磨损
Key words
CuNiIn coating /
CuNi4B coating /
atmospheric plasma spraying /
microhardness /
intersplat bonding /
fretting wear
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基金
国家自然科学基金重点项目（52031010, U1837201）
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