Preparation and Grinding Behavior of FeNi@SiC Magnetic Abrasives

CHENG Bo; YANG Bei; LIANG Jiabin; CHEN Ruirui; HOU Dong; ZHAO Xudong; LIANG Guodong; ZHANG Xinjian; LI Wensheng

doi:10.16490/j.cnki.issn.1001-3660.2025.24.014

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Surface Technology ›› 2025, Vol. 54 ›› Issue (24) : 173-183. DOI: 10.16490/j.cnki.issn.1001-3660.2025.24.014

Precision and Ultra-precision Machining

Preparation and Grinding Behavior of FeNi@SiC Magnetic Abrasives

CHENG Bo¹, YANG Bei¹, LIANG Jiabin², CHEN Ruirui¹, HOU Dong¹, ZHAO Xudong¹, LIANG Guodong¹, ZHANG Xinjian¹, LI Wensheng^1,3,*

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Abstract

The work aims to improve the phase conversion rate of the SiC abrasive particles in the magnetic abrasive and reduce the surface roughness of the ceramic layer of the thermal barrier coatings. The SiC abrasive particle phase was in-situ generated on the surface of the FeNi₅₀ spherical powder with C powder and Si powder, and the rotation speed and duration of mechanical ball milling as well as the sintering temperature were optimized. The microstructure and phase composition of the prepared abrasive, and the nano-hardness and elastic modulus of the magnetic-conductive phase as well as the abrasive particle phase were analyzed. Through the single-variable method, the optimal process parameters for preparing FeNi@SiC magnetic abrasive were determined. The magnetic abrasive obtained under these process conditions was used to conduct magnetic force grinding processing on the plasma-sprayed Gd₂Zr₂O₇ ceramic layer, reducing the surface roughness of the Gd₂Zr₂O₇ ceramic layer. The magnetic abrasive was analyzed with a scanning electron microscope (SEM), an X-ray diffractometer (XRD), and a nano-indentation tester, and the microstructure, phase composition of the magnetic abrasive, and the nano-hardness and elastic modulus of the magnetic-conductive phase as well as the abrasive particle phase were analyzed respectively. When the ball milling rotation speed was 100 r/min, the grinding phase could not completely wrap the matrix FeNi powder. When the ball milling rotation speed was 200 r/min, the C powder and Si powder were uniformly coated on the surface of the matrix FeNi powder. When the ball milling time was 5 h, the bonding between the grinding phase and the FeNi powder was poor. With the increase of the ball milling time, the C powder and Si powder were refined and the coating became more uniform. The coating effect was the best at 10 h. When the ball milling time was 15 h, the surface of the abrasive collided and rubbed, resulting in partial fragmentation and deformation. When the ratio of FeNi powder, C powder, and Si powder was 6 : 2 : 1, the shell-layer structure of the FeNi@SiC spherical powder was obvious. With the increase of the sintering temperature, the SiC phase was generated on the surface of the magnetic abrasive, and the content of SiC increased. With the ball milling parameters of 200 r/min and 10 h, the mass ratio of 6 : 2 : 1, the sintering temperature of 1 350 ℃, and the sintering time of 2 h, the prepared core-shell structured magnetic abrasive had SiC wrapped on the surface of the spherical FeNi powder. The content of SiC in the abrasive particle phase reached 32.2%, and the average nano-hardness of the abrasive particle phase was 11.31 GPa, showing excellent wear resistance. After the magnetic force grinding processing experiment, the Ra of the Gd₂Zr₂O₇ ceramic layer decreased from 15.8 μm to 2.08 μm, and the surface became smooth and flat. The core-shell structured FeNi@SiC magnetic abrasives are successfully prepared by the in-situ generation method with C powder and Si powder on the surface of FeNi₅₀ spherical powder. This method effectively improves the processing performance of the magnetic abrasives and reduces the surface roughness of the Gd₂Zr₂O₇ ceramic layer.

Key words

magnetic abrasive finishing / surface roughness / abrasive phase / nanohardness / thermal barrier coatings

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CHENG Bo, YANG Bei, LIANG Jiabin, CHEN Ruirui, HOU Dong, ZHAO Xudong, LIANG Guodong, ZHANG Xinjian, LI Wensheng. Preparation and Grinding Behavior of FeNi@SiC Magnetic Abrasives[J]. Surface Technology. 2025, 54(24): 173-183

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