目的 采用添加过渡层与同步复合电磁场方法,以降低轴承材料42CrMo表面激光熔覆铜合金涂层的孔隙率,提高其摩擦磨损性能。方法 在滑动轴承材料42CrMo表面熔覆铜合金,可以改善材料表面摩擦磨损性能并且降低制造成本,但铜与铁结合容易产生孔隙缺陷。本文通过添加过渡层以减少激光熔覆层的孔隙缺陷,基于正交试验设计对激光熔覆铜合金的工艺进行优化,研究了添加过渡层对熔覆层气孔的抑制作用。在此基础上,研究了电磁场对熔覆层组织与性能的影响。结果 最佳熔覆工艺为激光功率2 000 W,扫描速度2 mm/s,送粉速率8 g/min。通过添加Ni过渡层,熔覆层孔隙率最低可达0.1%,界面结合处无裂纹。无过渡层的熔覆层主要物相由α-Fe、（Fe,Ni）、Fe-Cr、α-Cu、CuNi2Sn、Cu41Sn11等组成;添加过渡层后熔覆层主要物相由α-Cu、CuNi2Sn、Cu41Sn11等组成,无球状富铁相,界面元素有明显过渡,结合良好。引入过渡层和电磁场后,组织呈弥散网状分布,优化后的熔覆层显微硬度为205.7HV0.3,干摩擦和油润滑条件下摩擦系数分别为0.367和0.118,磨损率分别为0.005×10-5 mm3·N-1·m-1和0.009×10-6 mm3·N-1·m-1,相比无过渡层试样降低了68.8%和35.7%,磨损形貌由黏着磨损转变为磨粒磨损。结论 过渡层的添加减少了因SnO2分解而产生的气孔,优化后熔覆层孔隙率显著降低,表层不含富铁相。电磁场产生的洛伦兹力会驱动熔体对流,促进成分均匀化。过渡层和电磁场的协同作用下,组织分布均匀,摩擦磨损性能大幅提升。
Abstract
In recent years, the "sliding instead of rolling" approach has become a new trend in wind power bearings to achieve cost reduction and efficiency improvement. However, sliding bearings are prone to fatigue spalling, abrasive wear, corrosion, melting and other failure forms when carrying. Cladding tin bronze on 42CrMo sliding bearing materials can enhance surface tribological properties while reducing manufacturing costs. However, direct Cu-Fe bonding tends to generate porosity defects. This study proposes employing a transition layer to mitigate pore formation in laser-clad coatings, while employing orthogonal experimental design to optimize the copper alloy cladding process. The transition layer significantly suppresses porosity in the cladding layer. Building on this approach, the influence of the electromagnetic field on the microstructure and properties of the cladding layer was thoroughly investigated. By adopting the method of adding a transition layer and synchronously applying a composite electromagnetic field, the porosity of the copper alloy coating on 42CrMo bearing materials via laser cladding was reduced, thereby improving its friction and wear performance.
The substrate material was 42CrMo bearing steel with dimensions of 240 mm×25 mm×10 mm. The surface oxide layer was removed with an angle grinder and cleaned with ethanol. The cladding material employed was gas-atomized CuSn12Ni2 powder, which was dried at 110 ℃ before the experiment. Single-pass cladding layers were prepared at laser powers of 1 600, 1 800, and 2 000 W, scanning speeds of 2, 4, and 6 mm/s, and powder feed rates of 8, 10, and 12 g/min. Multi-pass overlapping samples were fabricated at the optimal parameters with a 20% overlap rate. The cross-sectional morphology of the cladding layers was examined with an optical microscope. The microstructure was characterized by scanning electron microscopy, while an energy-dispersive spectroscopy was employed to analyze the elemental composition and distribution. Phase identification was conducted via X-ray diffraction, and microhardness was measured with a Vickers hardness tester. Sliding wear tests were performed at room temperature with a friction-wear tester, and the coefficient of friction was recorded. The 3D wear profiles were analyzed with a laser confocal profilometer, and the wear rates were calculated.
The optimal cladding process is achieved at a laser power of 2 000 W, a scanning speed of 2 mm/s, and a powder feed rate of 8 g/min. By incorporating the Ni transition layer, the porosity of the cladding layer can be minimized to 0.1%, with no cracks observed at the interfacial bonding region. Without the transition layer, the primary phases in the cladding layer consist of α-Fe, (Fe, Ni), Fe-Cr, α-Cu, CuNi2Sn, Cu41Sn11, whereas with the transition layer, the main phases are α-Cu, CuNi2Sn, Cu41Sn11, exhibiting a distinct elemental transition at the interface and ensuring excellent bonding. Under the combined action of the transition layer and the electromagnetic field, the microstructure exhibits a dispersed network morphology. The optimized cladding layer exhibits a microhardness of 205.7HV0.3. Under dry friction and oil lubrication conditions, the friction coefficients are 0.367 and 0.118, with corresponding wear rates of 0.005×10-5 mm3·N-1·m-1 and 0.009×10-6 mm3·N-1·m-1. Wear rates of the sample with the transition layer are reduced by 68.8% and 35.7%, respectively, compared with those without the transition layer. The wear mechanism shifts from adhesive wear to abrasive wear. The addition of the transition layer reduces porosity caused by the decomposition of SnO2, significantly lowering the porosity of the optimized cladding layer. The transition layer suppresses Fe diffusion from the substrate into the cladding layer, eliminating Fe-rich phases in the surface layer. The surface layer primarily comprises a matrix phase and island-shaped precipitates. The Lorentz force generated by the electromagnetic field drives melt convection, promoting compositional homogenization. Under the synergistic effect of the transition layer and electromagnetic field, the microstructure achieves uniform distribution, leading to significant improvement in tribological performance.
关键词
42CrMo /
激光熔覆 /
铜合金 /
过渡层 /
电磁场 /
孔隙率 /
摩擦磨损性能
Key words
42CrMo /
laser cladding /
copper alloy /
transition layer /
electromagnetic field /
porosity /
tribological properties
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基金
国家自然科学基金重点项目（52035014）; 浙江省“尖兵”研发攻关计划（2024SJCZX0040）; 浙江省高层次人才特殊支持计划（2023R5210）
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