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Deposition, microstructure and hardness of AlCoCrFeNi2.1 eutectic high entropy alloy coatings by cold spray, HVOF, and plasma spray 冷喷涂、HVOF 和等离子喷涂铝钴铬铁镍 2.1 共晶高熵合金涂层的沉积、微观结构和硬度
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131442
Jingjie Wei , Cristian Cojocaru , Maniya Aghasibeig , Chenwei Shao , Zehua Li , Jiahui Zhang , Eric Irissou , Yu Zou
Eutectic high entropy alloys (EHEAs) are reported to exhibit excellent mechanical properties which are useful for coating applications. In this study, we have produced AlCoCrFeNi2.1 EHEA coatings using the cold spray, high velocity oxygen-fuel (HVOF), and plasma spray techniques and compared their bonding characteristics, microstructure and hardness. We observe body-centered cubic (bcc) to face-centered cubic (fcc) phase transformations in all the types of coatings. The high processing temperatures in HVOF and plasma sprays lead to the segregation and depletion of Al from Ni-and Al-rich bcc/B2 regions and form Al2O3. In the cold sprayed coatings, we observe that a fraction of lamellar microstructure is preserved after cold spraying. Regarding the hardness, the cold sprayed coatings exhibit hardness in the range of 440–498 HV due to high work hardening and low oxygen content below 4 at.%; the HVOF coatings show the hardness in the range of 380–556 HV due to the effects of oxide dispersion strengthening with 13–28 at.% oxygen; The plasma sprayed coatings exhibit the hardness in the range 208–258 HV and 6.1–13.4 at.% oxygen. This study demonstrates the feasibility to produce thick and dense EHEA coatings using the above spray techniques, and the cold sprayed coatings exhibit relatively high hardness and low oxygen levels.
据报道，共晶高熵合金（EHEAs）具有优异的机械性能，可用于涂层应用。在这项研究中，我们采用冷喷、高速氧气燃料（HVOF）和等离子喷涂技术制备了 AlCoCrFeNi2.1 EHEA 涂层，并比较了它们的结合特性、微观结构和硬度。我们在所有类型的涂层中都观察到了体心立方（bcc）到面心立方（fcc）的相变。HVOF 和等离子喷涂的加工温度较高，导致铝从富含镍和铝的 bcc/B2 区域偏析和贫化，形成 Al2O3。在冷喷涂涂层中，我们观察到冷喷涂后保留了部分片状微观结构。在硬度方面，由于高加工硬化和低于 4%的低氧含量，冷喷涂层的硬度在 440-498 HV 之间；由于 13-28% 氧含量的氧化物分散强化效应，HVOF 涂层的硬度在 380-556 HV 之间；等离子喷涂涂层的硬度在 208-258 HV 和 6.1-13.4% 氧含量之间。这项研究证明了使用上述喷涂技术生产厚而致密的 EHEA 涂层的可行性，而且冷喷涂涂层具有相对较高的硬度和较低的氧含量。
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引用次数: 0
Surface modification of superduplex stainless steel with C and N: Microstructural and nanomechanical insights 用 C 和 N 对超级双相不锈钢进行表面改性：微观结构和纳米力学的启示
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131441
Alisiya Biserova-Tahchieva , Laia Ortiz-Membrado , Raúl Benítez , Oriol Rius-Ayra , Núria Llorca-Isern , Antonio Mateo , Emilio Jiménez-Piqué
In this study, the effect of thermochemical processes, such as nitriding and carburizing, on the microstructural evolution of superdúplex stainless steel is presented. The objective is to find a correlation between the microstructure and the mechanical properties of the constitutive phases of this stainless steel (i.e., austenite and ferrite) and analyze the diffusion elements influence on the precipitation of secondary phases, such as sigma (σ), chi (χ), nitrides, and carbides. Hardness (H) and elastic modulus (E) maps were obtained by using a high-speed nanoindentation technique. H and E values for the individual phases were determined through the application of Gaussian Mixture Model statistical analysis. Assessments of the mechanical properties of the different phases were achieved by overlaying field emission-scanning electron microscopy micrographs. An excellent correlation between microstructure and small-scale mechanical properties was attained. Secondary phases have been detected and nanoindentation statistics have proven their influence on the mechanical properties.
本研究介绍了氮化和渗碳等热化学过程对超孪晶不锈钢微观结构演变的影响。目的是找到该不锈钢的微观结构与构成相（即奥氏体和铁素体）机械性能之间的相关性，并分析扩散元素对次级相（如 sigma (σ), chi (χ), 氮化物和碳化物）析出的影响。使用高速纳米压痕技术获得了硬度（H）和弹性模量（E）图。通过应用高斯混合模型统计分析确定了各相的 H 值和 E 值。通过叠加场发射扫描电子显微镜显微照片，对不同相的机械性能进行了评估。微观结构与小尺度机械性能之间实现了良好的相关性。检测到了次生相，纳米压痕统计证明了它们对机械性能的影响。
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引用次数: 0
Microstructure and performance of compositionally graded Ta2O5/Ti thin films on Ti6Al4V alloy deposited by magnetron sputtering 通过磁控溅射沉积在 Ti6Al4V 合金上的成分分级 Ta2O5/Ti 薄膜的微观结构和性能
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131443
Haiyang Li , Yifan Ding , Xujun Hu , Wenyuan Li , Cuijiao Liao , Zeliang Ding
Tantalum pentoxide (Ta2O5) ceramic is a promising material for modifying metal implants due to its superior wear resistance, chemical stability, and biocompatibility. However, the clinical application of Ta2O5 coatings may be limited by inadequate adhesion, resulting from performance mismatches between Ta2O5 coatings and metal substrates. In this study, a Ta2O5/Ti gradient film was developed on the Ti6Al4V titanium alloy substrate using magnetron sputtering, consisting of a Ti bonding layer, four Ta2O5-Ti composite interlayers with graded composition, and a Ta2O5 surface layer. The microstructure and properties of the Ta2O5/Ti gradient films were investigated, with a Ta2O5 monolayer coating as a reference. Results reveal that the gradient layers have higher density, lower surface roughness, diminished residual thermal stress, and improved adhesion, mechanical properties, and wear resistance compared to the Ta2O5 monolayer coating. However, the corrosion resistance of the Ta2O5/Ti gradient layer sample is inferior to that of the Ta2O5 monolayer coating sample, attributed to interphase corrosion between Ta2O5 and Ti within the interlayers. These significant findings offer a promising approach for enhancing the overall performance of Ta2O5 coating on Ti6Al4V titanium alloy surfaces, thereby opening avenues for widespread application in the biomedical industry.
五氧化二钽陶瓷（Ta2O5）具有优异的耐磨性、化学稳定性和生物相容性，是一种很有前景的金属植入物改性材料。然而，Ta2O5 涂层的临床应用可能会受到粘附力不足的限制，这是因为 Ta2O5 涂层和金属基底之间的性能不匹配造成的。本研究利用磁控溅射技术在 Ti6Al4V 钛合金基底上开发了一种 Ta2O5/Ti 梯度膜，由一个 Ti 结合层、四个具有梯度成分的 Ta2O5-Ti 复合夹层和一个 Ta2O5 表面层组成。以 Ta2O5 单层涂层为参照，研究了 Ta2O5/Ti 梯度薄膜的微观结构和性能。结果表明，与 Ta2O5 单层涂层相比，梯度层密度更高、表面粗糙度更低、残余热应力更小、附着力、机械性能和耐磨性更好。不过，Ta2O5/Ti 梯度层样品的耐腐蚀性不如 Ta2O5 单层涂层样品，原因是夹层中的 Ta2O5 和 Ti 之间存在相间腐蚀。这些重要发现为提高 Ti6Al4V 钛合金表面 Ta2O5 涂层的整体性能提供了一种可行的方法，从而为其在生物医学领域的广泛应用开辟了道路。
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引用次数: 0
Oxygen plasma-assisted magnetron sputtering deposition of non-stoichiometric Y2O3 films: Influence of oxygen vacancies on etching resistance 氧等离子体辅助磁控溅射沉积非全度 Y2O3 薄膜：氧空位对抗蚀刻性的影响
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131448
Yi Wu , Shu Xiao , Yinong Chen , Wenlu Dong , Jiancheng Liu , Yong Huang , Kejun Shi , Shuyu Fan , Zishuo Ye , Guoliang Tang , Paul K. Chu
Yttrium oxide (Y2O3) films are widely used to protect equipment in plasma etching, a crucial technique in semiconductor processing, due to their exceptional resistance to plasma etching. Since oxygen vacancy affects the performance of Y2O3 and may impact physical etching resistance, the internal relationship necessitates further investigation. In this article, Y2O3 films with varying oxygen vacancy concentrations are prepared by reactive magnetron sputtering with the assistance of oxygen plasma. The formation and development of oxygen vacancies in cubic Y2O3 films and their impact on the physical etching resistance were investigated. The experiment results indicate that the accumulation of oxygen vacancies causes non-stoichiometry and the etching rate is significantly reduced. Combined with density-functional theory, it is revealed that oxygen vacancy distorts the lattice, which increases covalent Y–O bonding and the formation energy of atoms. Moreover, the vacancy line defects resulting from diffusion and aggregation of oxygen vacancies exert a similar influence on the adjacent yttrium and oxygen layers. The enhancement of physical etching resistance is attributed to the strengthened internal Y–O bonds led by increasing oxygen vacancy concentration in the cubic Y2O3 films without inducing phase transition. The discovery enriches the understanding of how plasma interacts with Y2O3, and the etching mechanism.
氧化钇（Y2O3）薄膜具有优异的抗等离子蚀刻性能，因此被广泛用于保护等离子蚀刻设备，这是半导体加工中的一项重要技术。由于氧空位会影响 Y2O3 的性能，并可能影响物理抗蚀刻性，因此有必要进一步研究其内部关系。本文在氧等离子体的帮助下，通过反应磁控溅射法制备了不同氧空位浓度的 Y2O3 薄膜。研究了立方 Y2O3 薄膜中氧空位的形成和发展及其对物理耐蚀性的影响。实验结果表明，氧空位的积累会导致非化学计量性，蚀刻速率会明显降低。结合密度函数理论，发现氧空位会扭曲晶格，从而增加共价 Y-O 键和原子的形成能。此外，氧空位扩散和聚集产生的空位线缺陷对相邻的钇层和氧层也产生了类似的影响。耐物理蚀刻性的增强归因于立方 Y2O3 薄膜中氧空位浓度的增加导致内部 Y-O 键的加强，而不会诱发相变。这一发现丰富了人们对等离子体如何与 Y2O3 发生相互作用以及蚀刻机理的认识。
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引用次数: 0
Effect of TaC content on microstructure and wear behavior of PRMMC Fe-TaC coating manufactured by electrospark deposition on AISI304 stainless steel TaC 含量对 AISI304 不锈钢电火花沉积法制造的 PRMMC Fe-TaC 涂层微观结构和磨损行为的影响
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131446
A.A. Burkov, P.G. Chigrin, M.A. Kulik
The Fe-TaC coatings on stainless steel by electrospark granule deposition in an anode mixture of iron granules and tantalum carbide powder were first obtained. The material deposition rate on the substrate increased with the TaC powder concentration growth in the anode mixture, facilitating the initiation of electrical discharges. X-ray analysis of deposited coatings shows the presence of the TaC, γFe, and αFe phases. The tantalum carbide concentration grows with an increase in the content of TaC powder in the anode mixture, from 2.4 to 14.8 vol%. The dependence of the wear rate of coatings on the concentration of tantalum carbide in the anode mixture had a parabola form, with a minimum of 5 vol%. However, with a further increase in the TaC concentration in the anode mixture, the wear rate of the coatings monotonically increased due to spalling of TaC grains due to a deficiency of the metal binder.
通过在铁颗粒和碳化钽粉末的阳极混合物中进行电火花颗粒沉积，首次在不锈钢上获得了 Fe-TaC 涂层。随着阳极混合物中 TaC 粉末浓度的增加，基底上的材料沉积速率也随之增加，从而促进了放电的启动。沉积涂层的 X 射线分析表明存在 TaC、γFe 和 αFe 相。碳化钽的浓度随着阳极混合物中 TaC 粉末含量的增加而增加，从 2.4% 增加到 14.8%。涂层磨损率与阳极混合物中碳化钽浓度的关系呈抛物线形式，最小值为 5%。然而，随着阳极混合物中碳化钛浓度的进一步增加，涂层的磨损率单调增加，这是由于金属粘合剂不足导致碳化钛晶粒剥落。
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引用次数: 0
Quantitative mechanism of abnormal hardening behavior of Ti6Al4V alloy strengthened by ultrasonic surface rolling 超声波表面滚压强化 Ti6Al4V 合金异常硬化行为的定量机制
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131445
Pengfei Sun , Chenxi Qu , Hao Zhong , Chenfeng Duan , Xiaoqiang Li , Shengguan Qu
In general, the outermost region of a metallic material has the highest hardness after surface mechanical strengthening. However, an abnormal surface hardening behavior was observed in Ti6Al4V alloy after the ultrasonic surface rolling process (USRP) in this work. The region with the highest surface hardening was not at the top surface but at the subsurface. By analyzing the distribution of grain size, dislocation density, texture, and kernel average misorientation (KAM) at different depths from the surface, and combining these findings with finite element analysis (FEA), the microstructural evolution underlying this abnormal surface hardening was elucidated. The microstructural characterization and FEA results indicate that the subsurface region underwent the most significant deformation. Subsequently, through the application of theoretical analysis, the potential mechanism of abnormal hardening of USRP treatment is described quantitatively for the first time. The results demonstrated that the hardening effect resulting from grain refinement was less pronounced, whereas the hardening effect resulting from dislocation pile-up was more prevalent. At the subsurface region of the USRP sample, a large number of interfaces resulted in the highest accumulation of dislocations in this area. Consequently, the subsurface region exhibited the highest microhardness, leading to the abnormal surface hardening phenomenon.
一般来说，金属材料在经过表面机械强化后，最外层区域的硬度最高。然而，在这项工作中，Ti6Al4V 合金在经过超声波表面滚压工艺（USRP）后出现了异常的表面硬化行为。表面硬化程度最高的区域不在顶面，而是在次表面。通过分析表面不同深度的晶粒大小、位错密度、纹理和核平均错向（KAM）分布，并将这些发现与有限元分析（FEA）相结合，阐明了这种异常表面硬化的微观结构演变。微结构表征和有限元分析结果表明，次表层区域发生了最显著的变形。随后，通过应用理论分析，首次定量描述了 USRP 处理异常硬化的潜在机制。结果表明，晶粒细化导致的硬化效应并不明显，而位错堆积导致的硬化效应则更为普遍。在 USRP 样品的次表层区域，大量的界面导致该区域位错堆积最多。因此，次表层区域的显微硬度最高，导致了异常的表面硬化现象。
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引用次数: 0
Fluorinated B-72 hybrid silver doped modified nanoparticle as a coating for biological corrosion protection of ancient bricks 作为古砖生物防腐涂层的氟化 B-72 混合掺银改性纳米粒子
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-09 DOI: 10.1016/j.surfcoat.2024.131411
Naijing Bu, Miaoting Ye, Kaiyi Wang, Rong Li, Qiang Zhen
In this paper, a superhydrophobic organic-inorganic composite coating containing fluorinated B72 hybrid methyl-modified silica/(Ag doped TiO2) by hexamethyldisilazane (HMDS) (H-SiO2/Ag/TiO2) was prepared by means of a mild and an environmental friendly method. Transparency, adhesion, hardness tests and photocatalytic performance were measured to determine the content of Ag in TiO2 which the TiO2/AgNO3 ratio is 0.008 g/mL. The synthesized Ag/TiO2 nanoparticles were characterized by X-ray diffraction (XRD), Raman spectra and transmission electron microscope (TEM). The highest contact angle of coated ancient bricks was 148.66° and the color change value of ΔE⁎ before and after coating was <5 which is within an acceptable range. The physical properties such as apparent porosity and water vapor permeability (ΔMp) were studied. After weathering from acid, alkali, salt, water and ultraviolet radiation, the bricks coated by the composite coatings still have good hydrophobicity that the contact angle were >120° and minor degree of surface corrosion comparing with the ancient bricks. The inhibitory effect of the composite coating on Staphylococcus aureus (S. aureus) and Escherichia coli (E. coli), and that on algae (Chlamydomonas and Dunaliella) were studied through bacteriostasis test and algae comparative experiments, respectively. Finally, the mechanism of the composite coating on antibacterial and anti-algae was studied. The results showed that the appearance of the ancient bricks was not changed after coating, and the anti-weathering, antibacterial and anti-algae properties of the ancient transformation were increased.
本文采用温和环保的方法制备了一种含氟 B72 混合甲基改性二氧化硅/（掺银 TiO2）的六甲基二硅氮烷（HMDS）超疏水有机无机复合涂层（H-SiO2/Ag/TiO2）。测量了透明度、附着力、硬度测试和光催化性能，以确定 TiO2 中的 Ag 含量（TiO2/AgNO3 的比例为 0.008 g/mL）。通过 X 射线衍射（XRD）、拉曼光谱和透射电子显微镜（TEM）对合成的 Ag/TiO2 纳米粒子进行了表征。涂覆古砖的最高接触角为 148.66°，涂覆前后的色变值ΔE⁎为 <5，在可接受范围内。对表观孔隙率和水蒸气渗透率（ΔMp）等物理性质进行了研究。经过酸、碱、盐、水和紫外线的风化后，涂有复合涂料的砖块仍具有良好的憎水性，接触角为 120°，与古砖相比，表面腐蚀程度较轻。通过抑菌试验和藻类对比实验，分别研究了复合涂层对金黄色葡萄球菌和大肠杆菌的抑制作用，以及对藻类（衣藻和杜纳藻）的抑制作用。最后，研究了复合涂层的抗菌和抗藻机理。结果表明，涂覆后古建砖的外观没有改变，古建改造的抗风化、抗菌和抗藻性能均有所提高。
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引用次数: 0
Protective graphene-based coatings for Zamak: Physical and electrochemical analysis 用于扎马克的石墨烯基保护涂层：物理和电化学分析
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-05 DOI: 10.1016/j.surfcoat.2024.131434
Raffaella Striani , Sonia Bagheri , Claudio Mele , Carola Esposito Corcione
Concerns surrounding the widespread use of hazardous materials have increased over time and have led numerous states to implement regulations aimed at preserving human and environmental health. In response, industries like metallurgy have gradually transitioned from traditional, hazardous technologies to safer alternatives, such as using polymeric coatings to protect metals from corrosion. This study focuses on evaluating the protective properties of non-functionalized graphene oxide-based coating (GC) and functionalized graphene oxide-based coating (FGC) on the zamak samples. First, the powders were analyzed from structural, morphological, and spectroscopic perspectives. The formation of amino-silica groups on the graphene oxide sheets was confirmed through SEM-EDS, XRD, and FTIR analyses, validating the success of the functionalization process. Granulometric analysis demonstrated a good dispersion of fillers in the mixtures. Cross's theoretical model was applied to the rheological experiments to find the optimum way of coating application on metallic substrates. The corrosion resistance of the coatings was evaluated using OCP, LSV, PS, EIS, and salt spray experiments. The results revealed that the functionalized graphene oxide coating provided superior corrosion protection compared to other coatings on Zamak samples. AFM topographic images, along with roughness measurements, indicated a significantly less corroded surface when using the functionalized graphene oxide coating. Additionally, Raman spectroscopy confirmed the protective effectiveness of the FGC coating against corrosion.
随着时间的推移，人们对广泛使用危险材料的担忧与日俱增，并促使许多国家实施了旨在保护人类和环境健康的法规。为此，冶金等行业逐渐从传统的危险技术过渡到更安全的替代技术，例如使用聚合物涂层保护金属免受腐蚀。本研究重点评估了非功能化氧化石墨烯涂层（GC）和功能化氧化石墨烯涂层（FGC）对扎马克样品的保护性能。首先，从结构、形态和光谱角度对粉末进行了分析。通过 SEM-EDS、XRD 和 FTIR 分析，确认了氧化石墨烯片上氨基硅基团的形成，验证了功能化过程的成功。粒度分析表明了混合物中填料的良好分散性。克罗斯理论模型被应用到流变实验中，以找到在金属基底上涂覆涂层的最佳方法。使用 OCP、LSV、PS、EIS 和盐雾实验评估了涂层的耐腐蚀性。结果表明，与 Zamak 样品上的其他涂层相比，功能化氧化石墨烯涂层具有更优越的防腐蚀性能。原子力显微镜地形图和粗糙度测量结果表明，使用功能化氧化石墨烯涂层后，表面的腐蚀程度明显降低。此外，拉曼光谱也证实了功能化氧化石墨烯涂层的防腐效果。
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引用次数: 0
Preparation of hollow MgO nanosorbents via the templating method and study of their adsorption mechanism 模板法制备空心氧化镁纳米吸附剂及其吸附机理研究
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-05 DOI: 10.1016/j.surfcoat.2024.131436
Shangxiao Liu , Zhenxue Liu , Junkai Zhao , Xiaoxuan Wei
The treatment of dye-containing wastewater has been a concern in recent years. Herein, we used laboratory-waste-skimmed cotton as a biotemplate and successfully synthesized MgO hollow tubular nanosorbents via a mild microwave solvent-thermal method. In adsorption experiments, the response surface methodology and Box–Behnken design were used to optimize and determine the optimal Mg(OAc)2 concentration (0.4 mol/L), skimmed cotton template mass (0.4 g), and calcination temperature for Congo red adsorption (600 °C). The adsorption process was comprehensively analyzed from thermodynamic and kinetic perspectives. Results showed that the adsorption process of MgO-urea template (MgO-UT) hollow nanosorbent conforms to the Dubinin–Radushkevich equation of the ion-exchange adsorption process and follows the pseudo-second-order kinetic model. The maximum amount of Congo red adsorbed by MgO-UT hollow nanosorbent is 3511.35 mg/g, demonstrating its excellent adsorption effect. Therefore, MgO hollow tubular nanosorbents prepared using biological templates can be used as novel organic dye adsorbents.
近年来，含染料废水的处理一直备受关注。本文以实验室废脱脂棉为生物模板，通过温和的微波溶剂热法成功合成了氧化镁空心管状纳米吸附剂。在吸附实验中，采用响应面方法和Box-Behnken设计对Mg(OAc)2的最佳浓度（0.4 mol/L）、脱脂棉模板质量（0.4 g）和刚果红的最佳煅烧温度（600 ℃）进行了优化和确定。从热力学和动力学角度对吸附过程进行了综合分析。结果表明，MgO-脲模板（MgO-UT）中空纳米吸附剂的吸附过程符合离子交换吸附过程的杜宾-拉杜什基维奇方程，并遵循伪二阶动力学模型。MgO-UT 中空纳米吸附剂对刚果红的最大吸附量为 3511.35 mg/g，表明其具有良好的吸附效果。因此，利用生物模板制备的氧化镁空心管状纳米吸附剂可用作新型有机染料吸附剂。
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引用次数: 0
Mathematical modelling and validation of the mechanical properties of HVOF-sprayed WC-12Co coatings considering the phase composition and defects generated at different process parameters 考虑到相组成和不同工艺参数下产生的缺陷，对 HVOF 喷射 WC-12Co 涂层的机械性能进行数学建模和验证
IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS
Surface & Coatings Technology
Pub Date : 2024-10-05 DOI: 10.1016/j.surfcoat.2024.131433
Subham Sarkar, Rajib Das, Partha Pratim Bandyopadhyay
The thermal spraying process involves many machine-based parameters or independent variables (fuel flow rate, oxygen flow rate, powder feed rate, stand-off distance and many others in the HVOF process). Any combination of these parameters produces only two measurable responses, namely, particle temperature and particle velocity. In this current work, first, the machine-based spray parameters are varied in specific ways to produce different particle temperatures at near-constant velocities and vice-versa. This approach has reduced the number of independent variables to only two. These two factors further influence the in-flight particle reactions, thereby affecting the phase composition and the microstructural defects in the as-sprayed coatings. The X-ray diffraction patterns of the as-sprayed coatings revealed the presence of W2C, W, Co3W9C4, and amorphous Co-W-C phases apart from the WC phase. The W2C and W originated owing to the decarburization of the WC phase. On the other hand, the dissolution of the carbide in molten binder led to the formation of Co3W9C4 and the amorphous Co-W-C phase. The nano-hardness of both the carbide and binder phases increased with an increase in particle temperature owing to a higher degree of decarburization and carbide dissolution respectively. The porosity was the most significant micro-structural defect present in the as-sprayed coatings. An increase in either particle temperature or velocity reduced the porosity present in the as-sprayed coatings. The mechanical properties (microhardness, elastic modulus and indentation fracture toughness) tend to improve as porosity decreases. A comprehensive mathematical model is proposed to predict the mechanical properties of as-sprayed coatings as a function of composition and defects. Finally, the process maps of mechanical properties were plotted in temperature-velocity space.
热喷涂工艺涉及许多基于机器的参数或自变量（HVOF 工艺中的燃料流速、氧气流速、粉末进给率、间距和许多其他参数）。这些参数的任何组合都只会产生两个可测量的响应，即颗粒温度和颗粒速度。在目前的工作中，首先以特定方式改变基于机器的喷雾参数，从而在速度接近恒定的情况下产生不同的颗粒温度，反之亦然。这种方法将自变量的数量减少到只有两个。这两个因素会进一步影响飞行中的粒子反应，从而影响喷涂涂层中的相组成和微观结构缺陷。喷涂涂层的 X 射线衍射图样显示，除 WC 相外，还存在 W2C、W、Co3W9C4 和无定形 Co-W-C 相。W2C 和 W 源自 WC 相的脱碳。另一方面，碳化物在熔融粘结剂中的溶解导致了 Co3W9C4 和无定形 Co-W-C 相的形成。随着颗粒温度的升高，碳化物相和粘结剂相的纳米硬度都会增加，这分别是由于脱碳和碳化物溶解的程度提高了。孔隙率是喷涂涂层中最显著的微观结构缺陷。颗粒温度或速度的增加都会降低喷涂涂层中的孔隙率。随着孔隙率的降低，机械性能（显微硬度、弹性模量和压痕断裂韧性）趋于改善。我们提出了一个综合数学模型，用于预测作为成分和缺陷函数的喷涂涂层的机械性能。最后，在温度-速度空间绘制了机械性能过程图。
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