宋厚生,孔令杰,张伟平,张峰,王泽鑫,陈靓瑜,章君,Dobuvyy Oleksand,芦笙.正交实验设计法优化大气等离子喷涂氧化铝涂层工艺参数[J].表面技术,2025,54(7):235-246, 259.
SONG Housheng,KONG Lingjie,ZHANG Weiping,ZHANG Feng,WANG Zexin,CHEN Liangyu,ZHANG Jun,Dobuvyy，Oleksand,LU Sheng.Optimizing of Process Parameters of Atmospheric Plasma Sprayed Alumina Coatings by Orthogonal Experimental Design[J].Surface Technology,2025,54(7):235-246, 259 |
| 正交实验设计法优化大气等离子喷涂氧化铝涂层工艺参数 |
| Optimizing of Process Parameters of Atmospheric Plasma Sprayed Alumina Coatings by Orthogonal Experimental Design |
| 投稿时间：2024-08-16 修订日期：2025-01-02 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.07.020 |
| 中文关键词: 大气等离子喷涂技术 氧化铝陶瓷涂层 涂层性能优化 正交实验设计 |
| 英文关键词:atmospheric plasma spraying technology alumina ceramic coating coating performance optimization orthogonal experimental design |
| 基金项目:江苏省外专百人计划(BX2022030) |
| 作者 | 单位 |
| 宋厚生 | 江苏科技大学 材料科学与工程学院，江苏 镇江 212100 |
| 孔令杰 | 江苏科技大学 材料科学与工程学院，江苏 镇江 212100 |
| 张伟平 | 航发优材镇江增材制造有限公司，江苏 镇江 212100 |
| 张峰 | 航发优材镇江增材制造有限公司，江苏 镇江 212100 |
| 王泽鑫 | 江苏科技大学 材料科学与工程学院，江苏 镇江 212100 |
| 陈靓瑜 | 江苏科技大学 材料科学与工程学院，江苏 镇江 212100 |
| 章君 | 昆山市检验检测中心，江苏 昆山 215300 |
| Dobuvyy Oleksand | 乌克兰马卡洛夫国立造船大学 材料科学与工程学院，米科拉伊夫 54025 |
| 芦笙 | 江苏科技大学 材料科学与工程学院，江苏 镇江 212100 |
|
| Author | Institution |
| SONG Housheng | School of Materials Science and Engineering, Jiangsu University of Science and Technology, Jiangsu Zhenjiang 212100, China |
| KONG Lingjie | School of Materials Science and Engineering, Jiangsu University of Science and Technology, Jiangsu Zhenjiang 212100, China |
| ZHANG Weiping | HFYC Zhenjiang Additive Manufacturing Co., Ltd., Jiangsu Zhenjiang, 212100 China |
| ZHANG Feng | HFYC Zhenjiang Additive Manufacturing Co., Ltd., Jiangsu Zhenjiang, 212100 China |
| WANG Zexin | School of Materials Science and Engineering, Jiangsu University of Science and Technology, Jiangsu Zhenjiang 212100, China |
| CHEN Liangyu | School of Materials Science and Engineering, Jiangsu University of Science and Technology, Jiangsu Zhenjiang 212100, China |
| ZHANG Jun | Kunshan Inspection and Testing Center, Jiangsu Kunshan 215300, China |
| Dobuvyy，Oleksand | School of Materials Science and Engineering, Admiral Makarov National University of Shipbuilding, Mykolayiv 54025, Ukraine |
| LU Sheng | School of Materials Science and Engineering, Jiangsu University of Science and Technology, Jiangsu Zhenjiang 212100, China |
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| 中文摘要: |
| 目的 研究大气等离子喷涂工艺参数对氧化铝涂层性能的影响，并探讨其影响机制，以获得一组优化的喷涂工艺参数。方法 使用大气等离子喷涂技术在GCr15轴承钢表面制备镍-铝黏接层和氧化铝工作层，采用正交实验设计方法，改变喷涂工艺参数中的电流、氩气流量、喷涂距离和预热道次，使用热电偶测量喷涂过程中涂层和基体的温度，并对所制备涂层的物相组成、微观结构、硬度、结合强度进行表征。结果 涂层的温度主要受到电流和氩气流量的影响。在喷涂后期，涂层的温度趋于稳定，预热道次对涂层的平衡温度无显著影响。涂层主要由α-Al2O3、γ-Al2O3组成，涂层中的γ-Al2O3含量与电流、氩气流量呈正相关。较高的电流、较低的氩气流量及较近的喷涂距离可以提高涂层的沉积效率，但过高的电流和氩气流量会增大涂层的孔隙率。涂层的硬度与γ-Al2O3含量、涂层温度呈正相关。结论 综合考虑了涂层的孔隙率、平均硬度和结合强度，确定了一组最佳工艺参数，电流为650 A，氩气流量为30 L/min，喷涂距离为120 mm，预热2道次。 |
| 英文摘要: |
| Atmospheric plasma spraying technology has emerged as a prevalent surface modification technique due to its straightforward operation, low cost, and broad material applicability. Alumina ceramic material, characterized by its outstanding hardness, stability, and electrical insulation properties, has demonstrated significant application potential. Nevertheless, in the plasma spraying process, the interaction among several parameters exerts a decisive influence on the coating properties. The impacts of spraying current, argon flow rate, spraying distance, and preheating times on the microstructure and mechanical properties of the coating were examined through orthogonal experimental design. The internal relationship between coating temperature and coating properties was disclosed by monitoring the temperature variation of the coating and the substrate during spraying with a thermocouple. In the experiment, GCr15 bearing steel pre-cut to the appropriate size was chosen as the base material, and the surface oil and oxide were eliminated through sandblasting pretreatment. Subsequently, a composite coating composed of a Ni5Al bonding layer and an Al2O3 working layer was fabricated on the substrate surface via plasma spraying technology. On the back of a 50 mm×50 mm×8 mm plate of GCr15 bearing steel, a temperature-measuring plate for inserting and fixing armored thermocouples was fabricated by employing the EDM drilling process. The thermocouple was connected to the temperature recorder, which was utilized to record the temperature of the substrate and the coating during the spraying process and investigate its temperature rise pattern. The phase composition, microstructure, porosity, hardness, and bonding strength of the coating were characterized with an X-ray diffractometer, a metallographic microscope, a hardness tester, and a universal testing machine. Through range analysis, the influence of the selected parameters on coating properties was quantified, and a set of plasma spraying parameters was optimized by considering the porosity, hardness, and bonding strength of the coating. The results indicated that during 20 spraying cycles, the coating temperature gradually rose with the plasma flame sweep. The rising rate of the coating temperature decelerated in the middle spraying stage and reached a state of heat balance in the later spraying stage, and the coating temperature tended to stabilize. The heating rate of the coating was primarily affected by the argon flow rate, while the equilibrium temperature was mainly influenced by the current and the argon flow rate. The influence of preheating times on the equilibrium temperature of the coating was insignificant. The prepared Al2O3 coating mainly consisted of α-Al2O3 and γ-Al2O3. Since the transition from γ-Al2O3 to α-Al2O3 required crossing an energy barrier, the transition was not fully accomplished within the studied heat input and coating temperature range below 600 ℃. The proportion of γ-Al2O3 was positively correlated with the melting degree of the powder, while a higher argon flow rate would reduce the proportion of α-Al2O3. The deposition efficiency of the coating was influenced by current, argon flow rate, and spraying distance. Among them, high current, argon flow rate, and spraying distance would significantly increase the coating porosity. The average hardness of the coating section was related to the melting state of the powder and showed a high positive correlation with the proportion of γ-Al2O3 and the coating temperature. The consistency of the hardness of the coating was high, and the subsequent deposition of the coating had no obvious tamping effect on the previous coating. Taking into account the porosity, hardness, and bonding strength of the coating, this study ultimately determined the optimal process parameters of the atmospheric plasma spraying alumina coating:current 650 A, argon flow rate 30 L/min, spraying distance 120 mm, and preheating twice. This combination of parameters not only ensured the high quality of the coating but also provided a reliable technical support for industrial applications. |
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