目的 采用热喷涂工艺制备WC基硬质涂层,是基材表面强化领域的一种高效技术手段。传统WC基涂层存在高温脱碳问题,耐磨损性能不足,亟需开发新的材料组分及技术手段以提升涂层的综合性能。方法 通过机械混合制备不同稀土添加量的稀土复合WC-10Co-4Cr-xCeO2（x=0%、1.0%、2.0%、3.0%、4.0%,质量分数）喷涂粉体。采用等离子喷涂技术,制备稀土改性WC-Co-Cr基涂层,系统研究了CeO2对复合涂层微观结构、硬度、结合强度及耐磨损性能的影响,分析了CeO2加入对喷涂涂层高温脱碳行为的影响规律。结果 试验结果表明,引入CeO2并未改变涂层的物相组成,当CeO2添加量为2.0%时,WC-10Co-4Cr-2.0%CeO2涂层硬度达到1 464HV0.5,相较未添加稀土的WC-10Co-4Cr涂层提升了42%,改性 WC涂层的结合强度较原始涂层提升了28.9%。此外,稀土改性形成的CeO2-Cr-WC连续包覆结构,并辅以热处理,通过降低局部氧分压和物理阻隔的共同作用,有效抑制了WC的高温脱碳。经热处理后,WC-10Co-4Cr-2.0%CeO2涂层的磨损量最低达1.8 mg,摩擦系数同步降低至0.547,表现出最佳的耐磨损性能。结论 CeO2加入可以有效提升涂层的硬度和耐磨损性能,稀土CeO2复合WC涂层可替代传统WC基涂层进行基材表面强化。
Abstract
In the field of substrate surface strengthening technology, the use of thermal spraying processes to fabricate WC-based hard coatings is widely adopted due to its high efficiency and excellent performance. However, conventional WC-based coatings are prone to decarburization during high-temperature spraying, leading to the partial decomposition of the hard WC phase into brittle W2C phase, which reduces the coating hardness and wear resistance, thereby limiting their service life under harsh operating conditions. To address this issue, it is imperative to optimize material composition and develop new modification technologies to enhance the overall performance of the coatings.
In this study, based on the WC-10Co-4Cr system, different mass fractions (x = 0wt.%, 1.0wt.%, 2.0wt.%, 3.0wt.%, and 4.0wt.%) of CeO2 were introduced as a rare-earth modifier via mechanical mixing to prepare a series of CeO2 composite WC-based spraying powders. Rare-earth-modified WC-Co-Cr-based composite coatings were fabricated on substrates through atmospheric plasma spraying (APS). The effects of CeO2 on the microstructure, hardness, bonding strength, and wear resistance of the composite coatings were systematically investigated, and the effect of CeO2 addition on the high-temperature decarburization behavior of the sprayed coatings was analyzed. The results indicated that the introduction of CeO2 did not significantly alter the phase composition of the coatings, with WC remaining as the primary hard phase. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analyses revealed that CeO2 tended to accumulate at the interlayer interfaces between WC and the Co binder phase. It interacted with Cr in the coating, forming localized agglomerations at the intersections of the lamellar structures, thereby optimizing the interfacial bonding. When the CeO2 addition was 2.0wt.%, the coating achieved a maximum microhardness of 1 464HV0.5, representing a 42% improvement compared to the unmodified WC-10Co-4Cr coating. The bonding strength also increased from 34.9 MPa to approximately 45.0 MPa, a 28.9% enhancement, demonstrating significant mechanical performance gains.
Further analysis showed that the addition of CeO2 effectively suppressed the high-temperature oxidation and decarburization of WC particles during spraying. Under high-temperature conditions, CeO2 reacted with Cr to form a continuous CeO2-Cr-WC encapsulation structure. This structure reduced the local oxygen partial pressure at the interfaces and acted as a physical barrier, significantly weakening the intensity of the W2C diffraction peaks in X-ray diffraction patterns, indicating markedly controlled decarburization. After heat treatment, the wear mechanism of the coatings remained predominantly abrasive wear. However, the WC-10Co-4Cr-2.0wt.% CeO2 modified coating exhibited the optimal wear resistance, with a mass loss of only 1.8 mg and a friction coefficient of 0.547. Wear surface morphology observations revealed that the modified coating surface was smoother, exhibiting only minor hard particle indentations and slight micro-cutting traces. Microcracks and delamination were significantly reduced, indicating improved structural integrity and damage resistance. In conclusion, the appropriate incorporation of CeO2 not only significantly enhances the hardness and bonding strength of WC-based coatings but also effectively inhibits high-temperature decarburization, thereby improving wear resistance. This study demonstrates the significant potential of rare earth oxide CeO2-modified WC-based coatings as a replacement for conventional WC-based materials in surface strengthening of critical components.
关键词
WC-Co-Cr /
CeO2改性 /
等离子喷涂 /
热处理 /
耐磨性能
Key words
WC-Co-Cr /
CeO2 modification /
plasma spraying /
heat treatment /
wear resistance
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基金
包头市科技计划项目（2022C2002）; 中国北方稀土（集团）高新技术有限公司项目（BFXT-2022-D-0026）
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