目的 球阀作为航空航天管道系统的关键控制部件,在高压工况下面临严重摩擦磨损问题,导致气密性劣化与可靠性下降。针对SUS 300系列不锈钢耐磨性不足的技术瓶颈,本研究采用超音速火焰喷涂技术在SUS 304基体表面制备Inconel 718涂层,研究涂层的微观组织和摩擦性能。方法 通过扫描电子显微镜、X射线衍射、电子背散射衍射及透射电子显微镜等多尺度手段表征涂层微观结构,利用显微硬度计、材料表面性能测试仪及激光共聚焦显微镜评估其力学与摩擦学性能。结果 结果表明,涂层中存在平均尺寸为2.26 μm的细小晶粒,并积累高达22.46×1014 m‒2的位错密度,同时还存在纳米尺度的γ′与δ强化相。其中,细小的晶粒、纳米析出相以及高水平的位错密度均会增加位错运动的难度。此外,涂层还具备高达‒798.7 MPa的残余压应力。这些多尺度协同的微观组织结构使涂层的显微硬度达550.7HV0.1,较基体（242.9HV0.1）提升126.72%。结合强度达61.79 MPa,表明涂层与基体结合良好。摩擦学测试显示,涂层平均摩擦系数为0.72,较基体（0.82）降低;磨痕宽度和深度分别减少25.32%和53.86%,体积磨损率降至1.74×10‒6 mm3/(N·m),耐磨性提升约52.59%。结论 HVOF制备的Inconel 718涂层通过细晶强化、纳米沉淀相强化及高位错密度等微观机制,显著提高了球阀表面硬度与耐磨性。
Abstract
As key control components in aerospace pipeline systems, ball valves face severe friction and wear under high-pressure conditions, leading to deterioration in airtightness and reliability. To overcome the wear resistance limitations of SUS 300-series stainless steels, this study employs High Velocity Oxy-Fuel (HVOF) spraying to apply Inconel 718 coatings on SUS 304 substrates and systematically investigates their microstructural evolution and influence on mechanical and tribological performance.
This study uses 30-60 mesh white alumina (aluminum oxide) as the abrasive for sandblasting treatment of SUS 304 substrates. The surface is roughened under compressed air pressure of 0.5-0.6 MPa and a spraying distance of 30-40 mm, achieving a surface roughness of ≥5 μm. The HVOF spraying is conducted with kerosene as the fuel at the following parameters: oxygen pressure of 0.9 MPa, flow rate of 2 000 L/min, fuel pressure of 0.84 MPa, flow rate of 5.9 g/h, powder feed rate of 58 g/min, and a spraying distance of 380 mm. Using these parameters, HVOF-sprayed Inconel 718 coatings with an average thickness of 464.2 μm and no apparent defects is produced. The microstructure of the coatings is characterized by virtue of advanced techniques such as Optical Microscope (OM), Scanning Electron Microscopy (SEM), Energy Dispersive Spectrometer (EDS) Electron Backscatter Diffraction (EBSD), X-ray Diffraction (XRD) and Transmission Electron Microscope (TEM). The microhardness of the coatings is tested with a Vickers hardness tester under a load of 100 g and a dwell time of 15 s. A reciprocating friction and wear test is conducted on the polished coating surface with a material surface performance tester, and the dynamic coefficient of friction is recorded. A Si3N4 ball with a diameter of 5 mm is selected, with a normal load of 20 N, sliding speed of 500 r/min, single stroke length of 5 mm, and a test duration of 30 min. Subsequently, laser confocal analysis is conducted to examine the morphology parameters of the wear track.
The experimental results show that the porosity of the coatings is at an excellent level, with a value of only 0.43%. During the HVOF process, oxides mainly consisting of chromium oxide form on the surface of the particles, which then lead to pore formation during the subsequent deposition process. The coatings comprise fine grains averaging 2.26 μm and exhibit a high density of geometrically necessary dislocations, reaching 22.46×1014 m‒2. Simultaneously, nanoscale γ' and δ strengthening phases are precipitated. Fine grains block dislocation motion by increasing grain boundary density; nanoscale precipitates trigger Orowan strengthening, hindering dislocation glide; and the high dislocation density enhances work hardening and promotes entanglement. Moreover, the coatings also have a residual compressive stress of up to ‒798.7 MPa. This multiscale synergy raises the coatings' microhardness to 550.7HV0.1, a 126.72% improvement over the substrate's 242.9HV0.1. Bonding strength test results indicate that the coatings are tightly bonded to the substrate, with an average bonding strength as high as 61.79 MPa. Friction and wear tests indicate that the coatings' average coefficient of friction (0.72) is significantly lower than that of the substrate (0.82); the wear track width (910.2 μm) and depth (31.1 μm) are reduced by 25.32% and 53.86%, respectively, and the volumetric wear rate decreases to 1.74×10‒6 mm3/(N·m), reflecting a wear resistance improvement of approximately 52.59%.
The findings demonstrate that HVOF-sprayed Inconel 718 coatings substantially improve the surface hardness and wear resistance of ball valves, supporting the durability design of aerospace high-pressure pipeline components.
关键词
球阀 /
超音速火焰喷涂 /
Inconel 718喷涂层 /
微观组织 /
显微硬度 /
耐磨性能
Key words
ball valve /
HVOF /
Inconel 718 coatings /
microstructure /
microhardness /
wear resistance
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基金
泰山产业领军人才项目（Tscx202306085）
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