目的 揭示高温条件下YSZ-CaF2涂层摩擦磨损行为演变规律及机理,提升航空发动机高温运动机构服役可靠性与寿命。方法 通过等离子喷涂技术制备YSZ-CaF2高温自润滑耐磨涂层,结合航空发动机运动机构摩擦副的实际服役工况,利用高温摩擦试验装置开展不同温度条件下涂层的摩擦磨损试验,获取摩擦系数、磨损率、微观形貌等特征。在此基础上,建立考虑热机耦合效应的球/涂层摩擦副有限元模型,并提出融合摩擦系数和磨损率随温度变化的磨损仿真方法,进而开展不同温度条件下接触压力、摩擦磨损等行为的准确模拟,探究高温下YSZ-CaF2涂层摩擦学行为演变规律及机制。结果 有限元仿真与赫兹理论解析解获取的接触压力结果一致,不同温度下涂层磨损体积仿真结果与试验结果的误差均小于3%,验证了有限元模型和磨损仿真方法的有效性。此外,随着温度升高,涂层表面ZrO2、Al2O3耐磨相和CaF2润滑相含量增加,并在涂层表面生成较为连续的起保护作用的氧化层,使得界面接触压力分布更为均匀、摩擦系数降低且磨损减小。结论 制备的YSZ-CaF2涂层在高温条件下具有较好的减摩抗磨性能,且提出的磨损仿真方法准确有效,可用于涂层摩擦学行为演变规律研究及磨损预测。
Abstract
With the continuous advancement of the aerospace field, the pursuit of extreme performance has driven further increases in the thrust-to-weight ratio and inlet temperature of aero-engines. As a result, the operating conditions of internal moving components have become increasingly severe, with friction and wear issues becoming more pronounced, posing significant challenges to the high-performance and reliable service of aero-engines. To reveal the evolution law and mechanism of friction and wear behaviors of YSZ-CaF2 coating at high temperature conditions, and to improve the reliability and service life of high-temperature moving components in aero-engine, the work aims to prepare a YSZ-CaF2 high-temperature self-lubricating and wear-resistant coating by plasma spraying technology. Combined with the actual service conditions of friction pairs in aero-engine moving components, friction and wear tests were conducted at different temperature conditions through a ball-on-surface reciprocating sliding mode within a high-temperature friction test device. The friction coefficient, wear rate, micromorphology, elemental composition, and phase composition characteristics were acquired by the three-dimensional force sensor, scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) and white light interferometry (WLI). On this basis, a finite element model of the ball/coating friction pair incorporating thermomechanical coupling effects was established by comprehensively applying tribology, thermodynamics, and finite element techniques. A wear simulation method integrating temperature-dependent friction coefficients and wear rates was proposed by adopting Archard wear theory and Arbitrary Lagrangian-Eulerian (ALE) adaptive meshing technology. Then, combined the established finite element model and the proposed wear simulation method, the simulation of contact pressure and tribological behavior at various temperatures was conducted to reveal the evolution and mechanisms of the tribological behavior of the YSZ-CaF2 coating at high temperatures. The experimental results show that as the temperature increases, both the friction coefficient and wear rate of the coating decrease. In addition, the content of wear-resistant phases (ZrO2 and Al2O3) and lubricating phase (CaF2) on the coating surface increases, forming a relatively continuous and complete oxide layer which provides protection. The simulation results indicate that the contact pressure obtained from the finite element simulation agrees well with the analytical solution derived from Hertz theory. The simulated wear volume of the coating at different temperatures shows less than 3% error compared to experimental measurements, validating the accuracy of the finite element model and the wear simulation method. Moreover, as the temperature increases, the surface contact pressure of the coating decreases and its distribution becomes more uniform. In general, as the temperature rises, the content of the CaF2 lubricating phase on the coating surface increases and the interfacial friction coefficient reduces. Furthermore, the higher concentrations of ZrO2 and Al2O3 wear- resistant phases significantly decrease coating wear and promote the formation of a relatively continuous and complete oxide layer, thereby improving the contact state of the ball/coating interface and resulting in a more uniform distribution of contact pressure. As a result, the coating exhibits significant friction-reducing and wear-resistant effects at high-temperature conditions. The research findings can provide theoretical and methodological guidance for the design of high-temperature self-lubricating and wear-resistant coatings and the service performance evaluation of high-temperature moving components in aero-engines.
关键词
YSZ-CaF2涂层 /
高温摩擦 /
磨损 /
摩擦系数 /
有限元仿真
Key words
YSZ-CaF2 coating /
high-temperature friction /
wear /
friction coefficient /
finite element simulation
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基金
国家科技重大专项（J2022-VI-0007-0038）
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