目的 研究Al2O3含量对冷喷涂Al/Ni-Al2O3复合材料显微组织和耐腐蚀性的影响规律。方法 通过冷喷涂技术在铸铁表面制备不同Al2O3含量的Al/Ni复合涂层,利用SEM、显微硬度计、万能试验机、电化学工作站和盐雾试验箱等分析涂层的组织结构、结合强度与腐蚀性能。采用调节Al2O3含量的方法,研究不同金属和不同Al2O3含量对涂层组织和性能的影响。结果 Al/Ni-Al2O3复合涂层结构致密,且孔隙率均小于0.5%。Al-Al2O3复合涂层的显微硬度在50HV0.3附近波动,Ni-Al2O3复合涂层的显微硬度平均值为262HV0.3。在Al-Al2O3复合涂层中,Al2O3含量20%涂层具有最佳的耐腐蚀性;而Ni-Al2O3复合涂层中,同样是Al2O3含量20%涂层的腐蚀速率最低,相比于基材降低96%。结论 经456 h盐雾试验后,Al/Ni-Al2O3复合涂层表面出现轻微腐蚀,并未出现裂纹和剥落现象。
Abstract
Cold spray technology offers significant advantages in enhancing the wear resistance and corrosion resistance of critical cast iron components. However, the cold spray process is prone to issues such as porosity and low bond strength, which limits its engineering applications in critical structural components. Therefore, metal-ceramic composite corrosion-resistant coatings were prepared through cold spray technology, with different metals (Al/Ni) and Al2O3 content (10%-30%) selected to achieve synergistic control of microstructure and properties.
Pure aluminium powder (Al), nickel powder (Ni), and aluminium oxide powder with a purity greater than 99.9% were selected as the spray materials for preparing Al/Ni-Al2O3 composite coating. Cast iron was used as the substrate material, and Al/Ni powder with different Al2O3 contents was uniformly mixed. A PCS-1000 cold spray system was employed to prepare the corrosion-resistant coatings. During spraying process, nitrogen was used as the propellant gas at a pressure of 4-5 MPa and temperatures of 500 ℃ and 870 ℃. The microstructure and corrosion morphology of the Al/Ni-Al2O3 composite coating were observed through a scanning electron microscope (SEM, Sigma500, Zeiss) and energy dispersive spectrometer (EDS), and the elements on the corroded surfaces were analyzed. The bond strength of the coating was tested with an INSTRON-3382 universal testing machine. The porosity of different metal-ceramic composite coating cross-sections was measured with the image analysis software Image-J. The micro-hardness of the coating was measured with a FALCON-500 Vickers hardness tester. Electrochemical potential polarisation curves and electrochemical impedance spectroscopy (EIS) tests were conducted on a Zahner ZENNIUM XC electrochemical workstation. Salt spray corrosion tests were conducted with a Q-FOG CCT 1100-type salt spray corrosion test chamber, with the test conducted in accordance with GB/T 10125—2012.
The study showed that the Al/Ni-Al2O3 composite coating had a dense structure, with porosity values below 0.5%. Lower porosity indicated better corrosion resistance. The micro-hardness of the Al-Al2O3 composite coating fluctuated around 50HV0.3. The average micro-hardness of the Ni-Al2O3 composite coating was 262HV0.3. Both metal-ceramic composite coatings enhanced the corrosion resistance of the substrate. In the Al-Al2O3 composite coating, the corrosion current density and corrosion rate decreased in the order of A-1>A-3>A-2. A-2 exhibited the best corrosion resistance, reducing the corrosion rate by 76% compared to the substrate. In the Ni-Al2O3 composite coating, the N-2 coating had the lowest corrosion rate, decreasing it by 96% compared to the substrate. Salt spray test results indicated that after 456 hours of exposure, the surface of the Al/Ni-Al2O3 composite coating showed minor corrosion but no cracks or peeling. This demonstrated the significant advantage of the coating in resisting neutral salt spray corrosion.
Cold spraying technology can be used to produce high-density, corrosion-resistant coatings. The corrosion resistance of nickel and the high chemical stability of Al2O3 are the primary reasons for the significant improvement in the corrosion resistance of the coating. The extremely low porosity and high bond strength of the coating and the incorporation of Al2O3 into the metal effectively enhance chemical stability and reduce corrosion occurrence.
关键词
冷喷涂 /
铸铁 /
孔隙率 /
耐腐蚀性 /
中性盐雾
Key words
cold spraying /
cast iron /
porosity /
corrosion resistance /
neutral salt spray
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