目的 针对传统不粘涂层耐磨性差、表面磨损后疏水性快速衰减等问题,提出一种离散Al2O3-40%TiO2（AT40）陶瓷凸起结构强化的聚四氟乙烯（PTFE）耐磨不粘涂层结构设计,在摩擦磨损中,通过高硬度的陶瓷凸起对摩擦副的支撑作用,避免PTFE被快速磨除,以提高不粘涂层的耐磨性。方法 首先,采用等离子喷涂半熔化粒子沉积具有高表面粗糙度的AT40陶瓷涂层;其次,采用PTFE填充AT40陶瓷涂层表面半熔化粒子凸起间的空隙,获得复合涂层。研究喷涂距离对AT40涂层表面结构的影响,揭示AT40涂层表面粗糙度对复合涂层耐磨性能及持久不粘性能的影响规律。结果 当喷涂距离从40 mm分别提高到80、120、150 mm时,等离子喷涂AT40陶瓷涂层的表面粗糙度先减小后增加,在喷涂距离为40 mm时,粗糙度Ra最高,为19.3 μm,Rz为220.4 μm。将该条件下制备的AT40陶瓷涂层表面涂覆PTFE面层后,在摩擦磨损25 000周后依然能够保持不粘性能,相较于传统的PTFE不粘涂层提升了约4倍。结论 大气等离子喷涂的高粗糙度AT40陶瓷底层与PTFE面层的复合耐磨不粘涂层具有优异的耐磨性能和持久的不粘性能,可大幅提升不粘烹饪器皿的使用寿命。
Abstract
Polytetrafluoroethylene (PTFE)-based non-stick coatings are widely used in cookware, however, they suffer from poor wear resistance and a rapid decline in hydrophobicity upon surface wear. In the present work, a novel structural design in which the PTFE coating is reinforced with discrete Al2O3-40%TiO2 (AT40) ceramic protrusions is proposed to improve the wear resistance. During friction, the high-hardness ceramic protrusions support the friction counterpart to prevent rapid wear loss of the PTFE and thereby enhancing the wear resistance of the non-stick coating and improving durable non-stick performance. Firstly, a dense AT40 coating is prepared on the 304SS substrate surface in order to improve the corrosion resistance of the composite coating with the roughness of Ra 6.5 μm. Secondly, semi-molten AT40 particles are deposited via plasma spraying to prepare an AT40 ceramic coating of high surface roughness with numerous AT40 mounds on the surface. Subsequently, PTFE is used to fill the gaps between the semi-molten AT40 particle mounds to form a composite coating. The influence of spraying distance on the surface structure of the AT40 coating is investigated, and the mechanism how the surface roughness of the AT40 coating affects the wear resistance and long-term non-stick performance of the composite coating is elucidated. Additionally, characterization of the AT40 coating surface morphology and roughness is performed with a laser confocal microscope and the cross-sectional microstructure and surface morphology of the composite coating are characterized by scanning electron microscopy. The porosity of the dense coating is quantified using image analysis. The durable non-stick property of the composite coating is characterized by evaluating both wear resistance and variations in water contact angle (WCA) before and after abrasion. Wear mechanism and surface structure evolution of the composite coating during the wear process are also investigated.
Results show that the bilayer AT40/PTFE composite coating with high roughness can be fabricated through hybrid plasma spraying and PTFE deposition. Under optimized parameters, the coating exhibits excellent interfacial bonding and defect-free internal structure without micro cracks or delamination. As the spraying distance increases from 40 mm to 80 mm, 120 mm, and 150 mm, the surface roughness of the plasma-sprayed AT40 ceramic coating initially decreases and then increases, which is highly dependent on the molten-state and impact velocity of the AT40 particles. At a spraying distance of 40 mm, the roughness reaches its maximum value at Ra 19.3 μm and Rz 220.4 μm. Wear resistance of monolithic PTFE coating versus AT40/PTFE bilayer coating is comparatively investigated through ball-on-disk tribological testing, the monolithic PTFE coating directly applied on grit-blasted 304SS exhibits a rapid friction coefficient surge from 0.20 to approximately 0.65 after only 5 000 cycles, indicating complete coating depletion. In contrast, the optimized AT40/PTFE bilayers sprayed in the distance of 40mm maintains a stable and low friction coefficient (below 0.5) even after only 25 000 cycles. Furthermore, wettability tests reveal that for the optimized AT40/PTFE composite coating, the water contact angle (WCA) only decreases from 133 o to 101o even after 25 000 cycles of standard friction while the contact angle of the conventional glass micro-ball reinforced PTFE decreases from 118o to 45o only after 5 000 cycles. This validates that the AT40/PTFE composite coating possesses significantly enhanced durable non-stick performance, offering a service life more than five times longer than that of the monolithic PTFE coating.
关键词
等离子喷涂 /
Al2O3-40%TiO2/PTFE复合涂层 /
表面微凸结构 /
耐磨性 /
疏水性
Key words
plasma spraying /
Al2O3-40%TiO2/PTFE composite coating /
micro surface protrusion /
wear resistance /
durable hydrophobicity
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