目的 针对铜表面硬度低、耐磨性不足及动态载荷下易失效等问题,本研究采用激光熔覆技术在紫铜表面制备Cu-x(16Cr-4ZrC)（x=1,2,3）复合涂层,揭示Cr-ZrC含量对涂层微观组织及力学性能的调控机制,优化涂层成分以实现综合性能的提升,为铜基材料在极端工况下的表面强化提供理论依据与技术支撑。方法 选用Cu、Cr和ZrC作为熔覆粉末,采用激光熔覆技术在60 mm×60 mm×20 mm的紫铜基底上制备三种不同比例的Cu-x(16Cr-4ZrC)（x=1,2,3）复合涂层;针对每种比例,分别制备了1 mm和5 mm厚度的涂层样品。通过XRD、SEM和EBSD等微观表征手段结合动态压缩试验、摩擦磨损测试及纳米压痕测试,揭示了涂层微观结构与力学性能之间的关联。结果 随着Cr-ZrC含量的提升,复合涂层的组织结构从离散层状逐渐转变为连续分布状;ZrC相在富Cr相与基体界面处发生偏聚,形成界面强化作用。材料晶体取向强度逐渐降低,晶粒尺寸明显细化,小角度晶界比例从56%增加至67%,位错密度显著上升,促使涂层显微硬度和压痕硬度明显提高,分别较基体最多提升4.5倍和1.9倍;在摩擦性能方面,涂层摩擦系数和磨损量较基体最多分别降低30%和43%;动态力学性能测试结果显示,涂层表现出显著的应变率敏感性和应变率强化效应,屈服强度、弹性模量随Cr-ZrC含量升高而升高,在2 000 s-1应变率下,三种涂层的屈服强度分别是基体的2.9倍、5.3倍和8.6倍,但由于晶界数量增多阻碍位错滑移,导致涂层塑性下降。结论 随着Cr-ZrC成分的添加,激光熔覆铜基复合涂层的力学性能与微观组织都得到显著改善,并且通过对比不同Cr-ZrC含量涂层的性能,发现Cu-32Cr-8ZrC涂层在耐磨性提升与塑性保留之间达到最佳平衡。本研究可为航空航天、海洋工程等关键构件的强化及修复提供重要参考。
Abstract
Copper and its alloys are widely utilized in aerospace (e.g., rocket engine combustion chambers, nozzles) and marine engineering (e.g., ship propeller blades) due to their exceptional thermal conductivity, electrical conductivity and corrosion resistance. However, their low surface hardness and poor wear resistance restrict applications under extreme conditions, making the fabrication of composite coatings to enhance friction and wear resistance of great engineering significance. Chromium (Cr) is highly valued in surface engineering for its high hardness, wear resistance, and corrosion resistance, while zirconium carbide (ZrC) is commonly chosen as a laser cladding material owing to its high melting point, hardness and structural stability in extreme high-temperature environments. The work aims to optimize coating composition for the synergistic improvement of hardness, wear resistance and plasticity, providing theoretical and technical support for surface strengthening of copper-based materials under extreme working conditions. Cu-x(16Cr-4ZrC)(x=1,2,3) composite coatings were prepared on pure copper surfaces via laser cladding with Cu, Cr and ZrC powder materials. The microstructure, grain orientation, grain size and proportions of low/high-angle grain boundaries were analyzed through X-ray diffraction (XRD), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Dynamic compression tests, nanoindentation, friction-wear tests and microhardness measurements were conducted to investigate the relationship between Cr-ZrC content and the microstructure and mechanical properties, systematically revealing the regulatory mechanism of Cr-ZrC content on the microstructure and mechanical properties of the coating. The results demonstrated that increasing Cr-ZrC content significantly improved the coating's microstructure and mechanical properties. As Cr-ZrC content increased, the composite coating's structure transitioned from discrete layers to a continuous distribution, with reduced porosity. ZrC phases segregated at the interface between Cr-rich phases and the substrate, forming interfacial strengthening. The crystal orientation strength decreased, the grain size was refined, the proportion of low-angle grain boundaries increased from 56% to 67%, and the dislocation density rose significantly, leading to a marked increase in microhardness and indentation hardness-improved by up to 4.5 times and 1.9 times compared to the substrate, respectively. However, the increased number of grain boundaries inhibited dislocation slip ability, resulting in decreased coating plasticity. In terms of tribological properties, the friction coefficient and wear volume decreased by up to 30% and 43% compared to the substrate, respectively. Dynamic mechanical property tests showed that the coating exhibited significant rate sensitivity and strain-rate strengthening effects, with yield strength and elastic modulus increasing with Cr-ZrC content. At a strain rate of 2 000 s-1, the peak strains of the three composite coatings were 0.137, 0.129, and 0.118, and the plastic deformation segment strain lengths were 0.128, 0.119, and 0.105, respectively. In conclusion, with the addition of Cr-ZrC, the mechanical properties and microstructure of the laser-cladded copper-based composite coatings are significantly improved. By comparing the properties of coatings with different Cr-ZrC contents, the Cu-32Cr-8ZrC coating is found to achieve an optimal balance between wear resistance improvement and plasticity retention, along with excellent wear resistance. This series of studies can provide important references for the strengthening and repair of critical components in aerospace, marine engineering, and other fields.
关键词
激光熔覆 /
Cu-x(16Cr-4ZrC)（x=1,2,3）复合涂层 /
微观组织 /
力学性能 /
显微硬度 /
摩擦系数
Key words
laser cladding /
Cu-x(16Cr-4ZrC)(x=1,2,3) composite coatings /
microstructure /
mechanical properties /
microhardness /
friction coefficient
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基金
安徽省高等学校自然科学研究重大项目（2023AH040036）; 安徽高校协同创新项目（GXXT-2023-025）; 安徽高校协同创新项目（GXXT-2023-006）; 合肥市自然科学基金项目（HZR2432）; 中国博士后科学基金第77批面上资助（2025M771320）; 安徽建筑大学博士后科学研究项目（2024QDHZ07）
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