目的 为提高汽轮机叶片的服役寿命,系统研究叶片上防水滴侵蚀的防护涂层,本文研究WC-10Co-4Cr和司太立涂层的抗水滴侵蚀（WDE）性能。方法 使用超音速火焰喷涂在17-4PH上分别制备WC-10Co-4Cr和司太立涂层,通过自主搭建的水蚀实验台进行WDE实验,评价不同涂层的抗WDE性能,并使用X射线对涂层物相进行分析,用扫描电子显微镜和光学显微镜对WDE形貌进行表征。结果 在相同冲击角度下,WC-10Co-4Cr涂层试样质量损失远远小于司太立涂层试样,随着冲击角度的提高,WC-10Co-4Cr涂层试样的质量损失基本不变,而司太立涂层试样在180 min时,60°和90°水滴侵蚀下试样的质量损失分别是30°下的2.38倍和2.89倍,分别损失了47.1 mg和63.1 mg;在90°下司太立涂层试样的最大侵蚀率为0.841 mg/min,是WC-10Co-4Cr涂层试样的8倍,且稳定水蚀率为0.21 mg/min,远超WC-10Co-4Cr涂层的0.008 mg/min。通过研究不同WDE损伤程度试样,其重新喷涂涂层后试样的抗WDE性能,发现在相同损伤状态下,司太立涂层试样的最大侵蚀率是WC-10Co-4Cr涂层试样的5倍,在1 mg/min左右,而稳定水蚀率为2.3倍。另一方面,无论是WC-10Co-4Cr还是司太立,2种损伤状态下的最大侵蚀率基本相同,而损伤严重试样的稳定水蚀率是损伤中等试样的2倍。结论 WC-10Co-4Cr涂层的抗WDE性能优于司太立涂层,且随着冲击角度的增大,2种涂层受到的侵蚀更加严重,且损伤程度中等的试样进行涂层修复,抗WDE性能更好。
Abstract
Water droplet erosion (WDE) is a complex abrasion phenomenon, which refers to the phenomenon that water droplets impact the surface of the object in the process of high-speed movement, resulting in impact, erosion and other destructive effects on the surface materials of the object. This erosion usually occurs in the fields of energy machinery (such as turbine blades), aerospace (such as aircraft wings) and marine engineering. When water droplets impact at high speed, they will produce local high pressure and impact force, which will lead to surface fatigue, peeling, wear and other damages and affect the service life and performance of parts. Therefore, it is particularly important to prepare WDE resistant coatings on core parts. In this work, the effects of different erosion angles and repair degrees on the WDE resistance of WC-10Co-4Cr and Stellite coatings were studied. WC-10Co-4Cr coatings and Stellite coatings were prepared by supersonic flame spraying (HVOF and HVAF) on 17-4PH, respectively. Water droplet erosion experiments were carried out on the self-built water erosion test bench to evaluate the water erosion resistance of the coatings. The test bench was mainly composed of a DC variable-frequency adjustable speed motor, a gearbox, an experimental box, an ultra-high pressure water pump, a lubricating oil station, a vacuum pump and a control cabinet. In order to reduce the experimental cost, a high-speed water jet system was used to produce high-speed liquid-solid impact velocity. At the same time, the entire sample disc rotated at a uniform speed (1 500 r/min) to ensure that all samples were impacted by periodic water jets under the same WDE conditions. The microstructure of the water erosion trace of the coating after the test was observed by optical microscope and scanning electron microscope and the phase of the coating was analyzed by X-ray diffractometer. Then, the element distribution of the coating section was observed by EDS analyzer and the microhardness of the two coatings was measured by microhardness tester. At the same impact angle, the mass loss of WC-10Co-4Cr coating sample was much less than that of Stellite coating sample. With the increase of the impact angle, the mass loss of WC-10Co-4Cr coating sample was basically unchanged, while the mass loss of Stellite coating sample under 60° and 90° water droplet erosion for 180 minutes was 2.38 times and 2.89 times of that under 30° respectively. At 90°, the maximum erosion rate of Stellite coating sample was 8 times higher than that of WC-10Co-4Cr coating sample and the stable water erosion rate was as high as 23 times. By studying the water erosion resistance of the two kinds of coatings repaired after water erosion damage, it was found that under the same damage state, the maximum erosion rate of Stellite coating sample was 5 times that of WC-10Co-4Cr coating sample, while the stable water erosion rate was 2.3 times. On the other hand, the maximum erosion rate at the two damage states was basically the same and the stable water erosion rate of the severely damaged sample was twice that of the moderately damaged sample. To sum up, the water erosion resistance of WC-10Co-4Cr coating is much higher than that of Stellite coating and with the increase of the impact angle, the erosion of the two coatings is more serious and the repair effect is better when the coating damage is medium.
关键词
WC-10Co-4Cr涂层 /
司太立涂层 /
冲蚀角度 /
耐WDE性
Key words
WC-10Co-4Cr coating /
Stellite coating /
erosion angle /
WDE resistance
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基金
新材料重大专项项目资助（2025ZD0610300）; 国家自然科学基金重点项目（U24B2050）; 四川省自然科学基金项目（2024NSFSC0958）
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