目的 为了提高电力金具耐磨性,并揭示常规和极端磨损工况下镀锌层的使用寿命。方法 采用热浸镀锌技术在试件表面形成一层镀锌层,与GCr15钢球构成摩擦副进行摩擦磨损试验,研究了不同磨损工艺下镀锌层的摩擦学性能,并利用扫描电子显微镜（SEM）和能谱仪（EDS）对磨损表面和摩擦副的形貌和元素组成进行分析。结果 随着磨损时间增加,镀锌层摩擦系数呈下降趋势,镀锌层的磨损质量升高至41.3 mg后保持稳定波动,O元素含量逐渐增加至28.16%。随着磨损载荷增加,平均摩擦系数下降至0.38。在较低和较高的旋转转速下分别具有较高的摩擦系数（0.53）和磨损质量（42.39 mg）,磨损表面Zn元素含量均较低。结论 在短时间、低载荷和中转速下,镀锌层表面凸起优先与摩擦副发生碰撞脱落,随后划伤磨损表面形成微犁沟痕迹,磨损机制主要为磨粒磨损和疲劳磨损。而在长时间、高载荷和低、高转速下,磨损表面与摩擦副接触面积增大,加重材料损失并产生大量热量,造成了氧化磨损。而一部分材料黏附在表面起润滑保护作用,造成了黏着磨损。
Abstract
This study presents a comprehensive investigation of the tribological properties of hot-dip galvanized layers surfaces, focusing on enhancing the wear resistance of power fittings materials. Through hot-dip galvanizing, a galvanized layer with excellent metallurgical bonding is formed on the substrate surface. The research further explores the service life of the galvanized layer under different wear conditions. Q345R steel plates are selected as the substrate. Prior to the experiment, the substrates undergo alkaline cleaning for oil removal and acid washing for rust removal. Subsequently, the substrate is sequentially immersed in a flux solution (comprising 40% zinc chloride and ammonium chloride) and a molten zinc bath (with zinc purity of 99.99%). The galvanized layer is then solidified through water cooling. Friction and wear specimens are prepared using wire cutting and mounted on the worktable of an HT-1000 type ball-on-disk high-temperature wear tester. The specimens are paired with GCr15 steel balls to form the friction couple. The tribological performance of the galvanized layer is systematically investigated under varying wear time (900, 1 800, 2 700, 2 600, and 4 500 seconds), wear loads (3, 6, 9, 12, and 15 N), and rotational speeds (200, 400, 600, 800, and 1 000 r/min). The wear loss before and after the friction and wear tests is measured with a precision electronic balance. The worn surfaces and grinding balls are analyzed by scanning electron microscopy (SEM) to observe their three-dimensional morphologies. Energy-dispersive spectroscopy (EDS) is employed to capture spectra at selected points, enabling elemental composition and content analysis. The results reveal that as wear time increases, the average friction coefficient exhibits a decreasing trend. The wear loss of the galvanized layer increases from 30.9 mg to 41.3 mg and stabilizes with minor fluctuations. The oxygen element content rises from 3.47% to 28.16%. The wear mechanisms evolve from abrasive and spalling fatigue wear to adhesive and oxidative wear. Under a 3 N wear load, the friction coefficient reaches as high as 0.67, while the material loss is minimal at 16.11 mg, indicating significant abrasive wear. With increasing wear load, the average friction coefficient decreases, but the wear loss increases, with adhesive wear becoming dominant. Analysis demonstrates that under lower rotational speeds, higher friction coefficients and lower wear losses are observed. Conversely, higher rotational speeds result in lower friction coefficients and higher wear losses. In both cases, severe adhesive wear occurs, and the zinc element content on the worn surfaces is relatively low. Under short-term, low-load, and medium-speed conditions, protrusions on the galvanized layer surface collide and detach first, scratching the worn surface to form micro-plowing grooves, thereby providing excellent protective effects for the power hardware. However, under long-term, high-load, and low/high-speed conditions, the contact area between the worn surface and the grinding ball increases, leading to easier lifting of the galvanized layer material, exacerbated material loss, and generation of significant heat, resulting in oxidative wear. Some material adheres to the surface, providing lubrication and protection, which reduces the average friction coefficient during the wear process. However, under low-speed conditions, severe adhesive wear still results in a relatively high average friction coefficient.
关键词
电力金具 /
热镀锌 /
镀锌层 /
磨损机制 /
摩擦学性能
Key words
power fittings /
hot-dip galvanizing /
galvanized layer /
wear mechanisms /
tribological properties
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基金
国家自然科学基金资助项目（52205334）; 湖南省自然科学基金项目（2025JJ40039）; 湖南省科技创新计划项目（2025RC4004）; 清华大学高端装备界面科学与技术全国重点实验室开放基金（SKLTKF24B18）
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