李旭强,李文生,翟海民1，马旭.Fe基非晶涂层厚度与其爆炸喷涂沉积特性及性能[J].表面技术,2023,52(5):140-148, 162.
LI Xu-qiang,LI Wen-sheng,ZHAI Hai-min1，MA Xu.Effect of Coating Thickness on Fe-based Amorphous Detonation Spraying Deposition Characteristics and Properties[J].Surface Technology,2023,52(5):140-148, 162 |
| Fe基非晶涂层厚度与其爆炸喷涂沉积特性及性能 |
| Effect of Coating Thickness on Fe-based Amorphous Detonation Spraying Deposition Characteristics and Properties |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.05.014 |
| 中文关键词: 殷瓦钢 Fe基非晶涂层 爆炸喷涂 冷却应力 结合强度 耐腐蚀性 |
| 英文关键词:invar alloy Fe-based amorphous coatings detonation spray cooling stress bonding strength corrosion resistance |
| 基金项目:国家自然科学基金（52075234，51901092）；甘肃省科技重大项目（21ZD4WA017）；甘肃省教育厅产业转化项目（17JR7WA017）；国家国合基地基金（2017D01003）；“111”计划（D21032） |
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| Author | Institution |
| LI Xu-qiang | School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China |
| LI Wen-sheng | School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China ;School of Materials Science and Engineering, Shandong University of Science and Technology, Shandong Qingdao 266590, China |
| ZHAI Hai-min1，MA Xu | School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China |
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| 中文摘要: |
| 目的 评估沉积厚度对Fe基非晶涂层在殷瓦钢基体上服役性能的影响。方法 利用爆炸喷涂在殷瓦钢表面沉积了4种不同厚度（dAC1≈50 μm，dAC2≈150 μm，dAC3≈250 μm，dAC4≈500 μm）的Fe基非晶涂层，采用扫描电子显微镜（SEM）、X射线衍射仪（XRD）、维氏显微硬度计、纳米压痕仪、液压式万能试验机、电化学工作站等，研究了涂层的微观结构、物相组成、显微硬度、弹性模量、残余应力、结合强度和电化学腐蚀特性。结果 不同厚度Fe基非晶涂层均未出现明显的晶化现象，AC1涂层的孔隙率明显较高（2.8%~1.4%），在厚度增至AC3时涂层与基体界面出现了明显的裂纹，且裂纹随着厚度的增加继续恶化，至AC4时在截面形貌上仅观察到少量界面结合连接区域；随着涂层厚度的增加，涂层孔隙率、冷却残余拉应力和结合强度显著降低，显微硬度和弹性模量略有上升。AC1涂层因形成了电偶腐蚀，从而加剧了基体腐蚀，不具备耐腐蚀防护能力。当涂层厚度达到AC3后，涂层的腐蚀电流密度小于基体的腐蚀电流密度，其腐蚀电位和极化电阻均高于基体的，且腐蚀电流密度随着厚度的增加继续降低，AC3级及更厚的Fe基非晶涂层对基体形成了有效防护。结论 Fe基非晶涂层的结合性能和耐蚀性与涂层厚度变化趋势相反，涂层沉积厚度应根据涂层的服役工况而定。在耐蚀性工况下涂层应达到AC3级或更厚。 |
| 英文摘要: |
| Fe-based amorphous coatings with various thicknesses (dAC1≈50 μm, dAC2≈150 μm, dAC3≈250 μm, dAC4≈500 μm) were successfully deposited on the invar alloy substrate by detonation spray to evaluate the effect of the coating thickness on its service performance. The microstructure, phase composition, microhardness, elastic modulus, residual stress, bonding strength and electrochemical corrosion properties of each coating sample were studied. The results showed that the XRD patterns of each coating showed a typical broad and diffuse peak between 30° to 55° of 2θ range, suggesting an amorphous nature of the coatings. By contrast, AC1 had the highest porosity of 2.8%, and then rapidly decreased to 1.4%, 1.0%, and 1.1% for AC2, AC3, and AC4, respectively, due to the shot peening of the subsequently sprayed particles. AC1 and AC2 were well bonded on the substrate with no cracks at the interface between the coating and the substrate, while when it came to AC3, obvious cracks could be observed, and the cracks further expanded when the coating thickness increased to AC4. Since the thermal expansion coefficient of the invar substrate (3.4×10–6 ℃–1) was smaller than that of the coating (12.5×10–6 ℃–1), the cooling stress of the coating was tensile stress, and decreased with the increase of the coating thickness, and the comprehensive residual stress of the coating therefore tended to decrease in tensile stress or increase in compressive stress, which was beneficial to the bonding between coating layers. However, the increase of coating thickness weakened the adaptability of the coating/substrate interface stress, promoted the generation of interface cracks, and reduced the bonding strength of the coating, from AC1/32.0 MPa to AC2/29.6 MPa, AC3/21.0 MPa and AC4/16.6 MPa. Moreover, AC1 had the worst corrosion resistance, and the corresponding corrosion current density (26.6×10–6 A/cm2) was even much higher than that of the uncoated substrate (3.401×10–6 A/cm2), which was due to the penetrating pores in this coating that allowed the electrolyte to pass through the pores and directly contact the substrate, resulting in galvanic corrosion between the coating and the substrate. And the coating acted as a cathode to accelerate the corrosion rate of the substrate. When the coating thickness increased to the grade of AC3, the corrosion current density of the coating was lower than that of the substrate, and the corrosion potential and polarization resistance were both higher, and the corrosion current density continued to decrease with the increase of thickness, indicating that AC3 and thicker Fe-based amorphous coatings could play an effective corrosion protection role. Overall, under different thickness grades, the bonding performance of Fe-based amorphous coatings is negatively correlated with corrosion resistance, hence, the deposition thickness of the coating should be determined according to the service conditions of the coating. And under the condition of corrosion resistance, the coating thickness shall reach AC3 level or thicker. If there are penetrating pores in the coating, galvanic corrosion of the large cathode and the small anode will be formed, resulting in the rapid failure of the protected substrate. |
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