Self-regeneration wear-resistant particle structure and preparation method thereof
By adopting a self-regenerated wear-resistant particle structure in the wear-resistant coating, the layered distribution of the bonded phase and wear-resistant particle phase is achieved by using thermal spraying technology, which solves the problem of attenuation of surface roughness and friction performance in the long-term use of the coating, and achieves continuous maintenance of wear-resistant performance and extended service life.
Patent Information
- Application Number
- CN202411753534.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-02
- Publication Date
- 2025-03-25
AI Technical Summary
The surface roughness and friction properties of existing wear-resistant coatings gradually decay during long-term use, resulting in reduced wear resistance and shortened service life, especially in extreme environments.
The self-regenerated wear-resistant particle structure is adopted, and the bonded phase and wear-resistant particle phase are distributed layerwise together through thermal spraying technology. The wear-resistant particle phase of the surface layer falls off during wear, and the wear-resistant particle phase of the lower layer is gradually exposed, achieving self-regeneration and stable maintenance of roughness.
It achieves stability of surface roughness and friction performance during wear, extends the service life of the coating, and shows excellent wear resistance in high friction, high temperature or harsh environments.
Smart Images
Figure CN119685740A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to material processing technology, and more specifically to a self-regenerating wear-resistant particle structure and a preparation method thereof. Background Art
[0002] Wear-resistant coatings are widely used in petrochemical, aerospace, shipbuilding and other modern industrial and military fields, significantly improving the wear resistance of metal components, extending the service life of components and reducing maintenance costs. Wear, as a surface phenomenon, directly affects the performance of materials and is closely related to the surface properties, structure and working environment of the materials. Common mechanisms in the wear process include abrasive wear, fretting wear, adhesive wear, fatigue wear, oxidative wear and tribochemical reactions. By modifying the surface of the material with a coating, its wear resistance can be effectively enhanced, thereby reducing surface damage caused by wear and extending the service life of the product.
[0003] At present, coating technology, as one of the important means to improve the wear resistance of materials, has been widely used in many fields. Common coating preparation methods include physical vapor deposition, chemical vapor deposition, hybrid physical-chemical vapor deposition and atmospheric plasma spraying technology. Atmospheric plasma spraying technology has been widely used in industry due to its advantages such as simple process, high deposition efficiency, controllable coating thickness and wide application of materials. However, although thermal spray coatings have high deposition efficiency, there is still a phenomenon that key parameters of wear-resistant coatings such as surface roughness continue to decay with the use time during use. This decay not only leads to an increase in the friction coefficient of the coating surface, but also gradually reduces the wear resistance of the coating, which ultimately affects the service life of the coating, especially when used in high friction, high temperature or harsh environment. The performance decay of the coating is particularly obvious. Therefore, how to effectively solve the decay of surface roughness and friction performance of the coating during long-term use has become a key issue that needs to be broken through in wear-resistant coating technology.
[0004] At present, research on wear-resistant coatings at home and abroad mainly focuses on improving the hardness, wear resistance and friction performance of coatings. In particular, research on nanomaterials and microstructures provides new ideas for improving coating performance. However, most existing coating technologies still fail to solve the problem of the gradual decrease in the friction coefficient and roughness of the coating surface during long-term wear. Especially in extreme working environments, coatings often face the problem of short service life. Although there have been advances in technical means such as coating material selection, surface texture design and structural optimization, the existing technology still lacks a mature solution that can maintain stable wear resistance during wear. Summary of the invention
[0005] In order to solve the above-mentioned shortcomings of the prior art such as the friction coefficient decreasing with the use time, the present invention provides a method for preparing a self-regenerating wear-resistant particle structure and the self-regenerating wear-resistant particle structure obtained thereby.
[0006] According to the self-regenerating wear-resistant particle structure of the present invention, it includes a bonding phase and a wear-resistant particle phase, wherein the wear resistance of the bonding phase is less than that of the wear-resistant particle phase, the wear-resistant particle phase is distributed in layers in the bonding phase, the surface wear-resistant particle phase protrudes from the surface layer of the bonding phase to limit the rough surface of the self-regenerating wear-resistant particle structure, and after the surface wear-resistant particle phase falls off during the wear process, the lower wear-resistant particle phase is gradually exposed to achieve self-regeneration.
[0007] In a preferred embodiment, the wear-resistant particle phase is a layered structure dispersed and embedded in the binder phase, and each layer includes a plurality of spherical and nearly spherical hard particles.
[0008] In a preferred embodiment, the binder phase accounts for 60%-80% of the total mass of the self-regenerating wear-resistant particle structure, and the wear-resistant particle phase accounts for 20%-40% of the total mass of the self-regenerating wear-resistant particle structure.
[0009] In a preferred embodiment, the thickness of the self-regenerating wear-resistant particle structure is 0.15 mm to 2 mm.
[0010] According to the preparation method of the above-mentioned self-regenerating wear-resistant particle structure of the present invention, a thermal spraying method is adopted to simultaneously heat the first powder to a completely melted or nearly completely melted state, and heat the second powder to a semi-melted or slightly melted state, and the particles of the first powder wrap the particles of the second powder to form a self-regenerating wear-resistant particle structure, wherein the dense bonding phase formed by the solidification of the first powder after melting provides bonding to the wear-resistant particle phase.
[0011] In a preferred embodiment, the thermal spraying method is atmospheric plasma spraying, conventional flame spraying or supersonic flame spraying.
[0012] In a preferred embodiment, a coaxial double powder feeding method is used, the first powder is fed into the ion flow transmitted along the central axis of the plasma gun through the first powder feeder, and the second powder is fed into the ion flow transmitted along the central axis of the plasma gun through the second powder feeder in front of the first powder feeder. During the transmission process, the first powder is simultaneously heated to a completely melted or nearly completely melted state, and the second powder is heated to a semi-melted or slightly melted state. In the plasma flame flow, the particles of the completely melted or nearly completely melted first powder wrap the particles of the semi-melted or slightly melted second powder to form a self-regenerating wear-resistant particle structure.
[0013] In a preferred embodiment, the average particle size of the first powder is 15 μm-30 μm, the average particle size of the second powder is 35 μm-50 μm, and the distance between the second powder feeder and the first powder feeder is 41 mm-80 mm.
[0014] In a preferred embodiment, the feeding speed of the first powder is 10 g / min-20 g / min, and the feeding speed of the second powder is 20 g / min-40 g / min.
[0015] In a preferred embodiment, the particle size of the first powder is smaller than the particle size of the second powder.
[0016] According to the self-regenerating wear-resistant particle structure of the present invention, the wear-resistant particle phase is distributed in layers in the bonding phase, and has the advantages of high wear resistance, high stable roughness (stable friction coefficient), self-regeneration, long life and adjustable roughness coefficient. It not only has excellent wear resistance and controllable surface roughness, but also the surface roughness and surface friction coefficient do not change with service time during the friction and wear process, thereby ensuring a longer service life. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Figure 1 It is a schematic structural diagram of a self-regenerating wear-resistant particle structure according to a preferred embodiment of the present invention.
[0018] Figure 2 yes Figure 1 Schematic diagram of the wear process and roughness regeneration of the wear-resistant coating.
[0019] Figure 3 The surface morphology of the wear-resistant coating of Example 1 is shown.
[0020] Figure 4 yes Figure 3 Magnified image of .
[0021] Figure 5 The first cross-sectional morphology of the wear-resistant coating of Example 1 is shown.
[0022] Figure 6 yes Figure 5 Magnified image of .
[0023] Figure 7 The first cross-sectional morphology of the wear-resistant coating of Example 1 is shown.
[0024] Figure 8 yes Figure 7 Magnified image of .
[0025] Fig. 9 The cross-sectional morphology of the wear-resistant coating of Example 1 is shown.
[0026] Fig.10 yes Fig. 9 Magnified image of . DETAILED DESCRIPTION
[0027] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.
[0028] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.
[0029] like Figure 1 As shown, the self-regenerating wear-resistant particle structure 1 according to the present invention is connected to the base material 3 through the bonding layer 2, and specifically includes a bonding phase 11 and a wear-resistant particle phase 12, wherein the wear-resistant particle phase 12 is distributed in the bonding phase 11 in a layered manner, and the surface wear-resistant particle phase 12 is convex from the surface layer of the bonding phase 11 to define the rough surface of the self-regenerating wear-resistant particle structure 1, as shown in FIG. Figure 2 As shown, after the wear-resistant particle phase 12 of the surface layer falls off during the wear process, the wear-resistant particle phase 12 of the lower layer is gradually exposed to achieve self-regeneration.
[0030] The wear-resistant particle phase 12 is a layered structure dispersed and embedded in the binder phase 11 , and each layer includes a plurality of spherical and nearly spherical hard particles. In particular, the layered structure of the wear-resistant particle phase 12 is uniformly distributed in the binder phase 11 .
[0031] In a preferred embodiment, the binder phase 11 accounts for 60%-80% of the total mass of the self-regenerating wear-resistant particle structure 1 , and the wear-resistant particle phase 12 accounts for 20%-40% of the total mass of the self-regenerating wear-resistant particle structure 1 .
[0032] In a preferred embodiment, the thickness of the self-regenerating wear-resistant particle structure 1 is 0.15 mm to 2 mm. It should be understood that the thickness can be adjusted according to different usage scenarios.
[0033] like Figure 1 As shown, in the initial state, the lower half of the wear-resistant particle phase 12 of the surface layer is buried in the bonding phase 11, while the upper half is protruded from the bonding phase 11, thereby providing a rough surface through the upper half of the protruded wear-resistant particle phase 12. Figure 2 As shown, during the wear process, the surface wear-resistant particle phase 12 is preferentially worn and peeled off due to the exposure of the upper half, and then the surface bonding phase 11 is preferentially worn due to its lower wear resistance relative to the wear-resistant particle phase 12, so that the upper half of the wear-resistant particle phase 12 of the lower layer is exposed from the bonding phase 11 of the lower layer (with a hemispherical structure convex), so that the roughness is maintained through the upper half of these convex wear-resistant particle phases 12, and the roughness self-regeneration during the wear process is achieved. In this way, the self-regenerating wear-resistant particle structure 1 achieves self-regeneration through the layered exposure and peeling of the bonding phase 11 and the wear-resistant particle phase 12, maintains the stability of the roughness of the self-regenerating wear-resistant particle structure 1 during use, and combines with a stable high friction coefficient to greatly improve the service life of the self-regenerating wear-resistant particle structure 1, expand the scope of use of the self-regenerating wear-resistant particle structure 1, and make it widely used in the fields of material processing, aerospace, energy and power, shipbuilding, etc.
[0034] The preparation method of the self-regenerating wear-resistant particle structure according to the present invention comprises cleaning and roughening the surface of the base material 3, and then providing the bonding layer 2 on the base material 3. In a preferred embodiment, the surface cleaning is performed by ultrasonic cleaning, and the roughening treatment is sandblasting. The bonding layer 2 is a Ni-22Cr-10Al-1Y material layer. The base material 3 is a metal matrix, including an iron-based alloy (or ordinary alloy steel, or stainless steel), an aluminum alloy, copper, or a Ni-based alloy, such as GH-5188 nickel-based alloy.
[0035] The preparation method of the self-regenerating wear-resistant particle structure according to the present invention includes adopting a thermal spraying method, and simultaneously heating the first powder to a completely melted or nearly completely melted state, and heating the second powder to a semi-melted or slightly melted state, and the particles of the first powder wrap the particles of the second powder, and after colliding with the matrix material 3, they are deposited on the surface of the matrix material 3 to form a self-regenerating wear-resistant particle structure 1, wherein the second powder provides a wear-resistant particle phase 12 as a wear-resistant phase, and the dense bonding phase 11 formed by the first powder after melting and solidification provides bonding to the wear-resistant particle phase 12, such as Figure 1 shown.
[0036] In a preferred embodiment, the thermal spraying method is atmospheric plasma spraying, ordinary flame spraying, or supersonic flame spraying. In a preferred embodiment, a coaxial double powder feeding method is used to prepare the self-regenerating wear-resistant particle structure 1. Specifically, the first powder is fed into the ion flow transmitted along the central axis of the plasma gun through the first powder feeder, and the second powder is fed into the ion flow transmitted along the central axis of the plasma gun through the second powder feeder in front. During the transmission process, the first powder is heated and melted, and the second powder is evenly dispersed in the first powder.
[0037] In a preferred embodiment, the wear resistance of the first powder is less than that of the second powder, and the second powder has high hardness and high wear resistance. In a preferred embodiment, the first powder has good high hardness and high wear resistance, and the second powder is a solid homogeneous particle with high melting point, high hardness and high wear resistance. In a preferred embodiment, the hardness of the second powder is greater than 800Hv, more preferably greater than 1000Hv, and its hardness is significantly greater than the hardness of the base material 3. In a preferred embodiment, the first powder and the second powder are respectively micron-grade materials and / or nano-grade materials. In a preferred embodiment, the particle size of the first powder is smaller than the particle size of the second powder, so that the first powder can completely wrap the second powder after melting. In a preferred embodiment, the first powder is a nano-grade powder and the second powder is a micron-grade powder. In a preferred embodiment, the first powder and the second powder are YSZ powders, respectively. It should be understood that there are no requirements for the preparation methods of the first powder and the second powder, and there are no requirements for the powder particle size. It should be understood that the specific description of the materials of the first powder and the second powder above is only for example and not for limitation. It should be understood that the first powder and the second powder preferably have similar physical properties, such as thermal expansion coefficient. When the self-regenerating wear-resistant particle structure 1 is worn, the surface will generate a lot of heat due to friction, and the surface temperature will rise. Similar thermal expansion coefficients can reduce cracks and failures caused by different expansion coefficients.
[0038] It should be understood that the self-regenerating wear-resistant particle structure 1 has an adjustable roughness coefficient, which is achieved by adjusting thermal spraying parameters and changing material size, such as changing the particle size of the first powder and the second powder, or changing the porosity of the second powder.
[0039] The present invention is further described in detail below with reference to specific embodiments and drawings.
[0040] Example 1
[0041] YSZ powder is used as powder feeding material, the composition of YSZ material is 7-8% Y2O3-ZrO2, the metal matrix uses GH-5188 nickel-based alloy, and the metal matrix is ultrasonically cleaned and sandblasted.
[0042] The self-regenerating wear-resistant particle structure 1 was prepared by using the F4-MB atmospheric plasma spraying system (Oerlikon Metco, Switzerland). A certain thickness of bonding layer was first prepared on the metal substrate using Ni-22Cr-10Al-1Y material, and then the self-regenerating wear-resistant particle structure was sprayed using a coaxial double powder feeding method. The first powder was completely melted and the second powder was semi-melted or slightly melted. The two particles were deposited on the prefabricated bonding layer. The first powder formed a bonding phase 11 and a filling phase, and the wear-resistant particle phase 12 formed by the second powder was bonded together to form a self-regenerating wear-resistant particle structure 1 with high wear resistance, self-regeneration, long life and adjustable friction coefficient. Figure 3 -As shown in 10, the surface of the self-regenerating wear-resistant particle structure 1 is rough, showing a large number of hemispherical particles convex surface, and there are a large number of spherical and nearly spherical unmelted wear-resistant particles inside the coating. These wear-resistant particles are evenly distributed to form the self-regenerating wear-resistant particle structure 1.
[0043] In Example 1, the first powder is YSZ powder with an average particle size of 15 μm, and the second powder is YSZ powder with a particle size of 35 μm. The preheating power of the F4-MB atmospheric plasma spraying system is 38 W, the spraying power is 42 KW, the gun distance from the plasma spray gun to the substrate is 80 mm, the gun speed is 800 mm / min, the first powder is carried by hydrogen to fly toward the substrate, and the powder feeding speed is 10 g / min. The second powder 2 is carried by argon to fly toward the substrate, and the powder feeding speed is 30 g / min. The distance between the first powder feeder and the plasma spray gun is 5 mm, and the distance between the second powder feeder and the first powder feeder is 41 mm. The hardness is 824.1 Hv. The self-regenerated wear-resistant particle structure 1 obtained has good wear resistance, and the measured roughness Ra is 5.16.
[0044] In Example 2, the first powder is YSZ powder with an average particle size of 30 μm, and the second powder is YSZ powder with a particle size of 50 μm. The preheating power of the F4-MB atmospheric plasma spraying system is 38 W, the spraying power is 42 KW, the gun distance from the plasma spray gun to the substrate is 80 mm, the gun speed is 800 mm / min, the first powder is carried by hydrogen to fly toward the substrate, and the powder feeding speed is 20 g / min. The second powder 2 is carried by argon to fly toward the substrate, and the powder feeding speed is 40 g / min. The distance between the first powder feeder and the plasma spray gun is 15 mm, and the distance between the second powder feeder and the first powder feeder is 60 mm. The self-regenerated wear-resistant particle structure 1 obtained has good wear resistance, a hardness of 949.6 Hv, and a measured roughness Ra of 4.67.
[0045] Obviously, by adjusting the particle size and powder feeding speed of the first powder and the second powder, and changing the positions of the first powder feeder and the second powder feeder in the plasma flame flow, the present invention can obtain a self-regenerating wear-resistant particle structure with adjustable roughness. The smaller the roughness, the better the wear resistance. By using two different powders, the toughness and hardness required for the coating can be provided to the self-regenerating wear-resistant particle structure, thereby increasing the life of the coating.
[0046] In the comparative example, the melting degree of the second powder is too large. After melting, the powder aggregates together and there are certain cavities inside. This causes the hard particles inside the coating to be unevenly dispersed. The randomly appearing cavity areas cause the hardness of the final coating to drop sharply to 555.3Hv, which is not suitable for making self-regenerating wear-resistant particle structures.
[0047] The above is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. The above embodiment of the present invention can also be modified in various ways. That is, all simple, equivalent changes and modifications made according to the claims and the description of the present invention fall within the scope of protection of the claims of the present invention. The contents not described in detail in the present invention are all conventional technical contents.
Claims
1. A self-regenerating wear-resistant particle structure, characterized in that: The self-regenerating wear-resistant particle structure includes a bonding phase and a wear-resistant particle phase, wherein the wear resistance of the bonding phase is less than that of the wear-resistant particle phase, the wear-resistant particle phase is distributed in layers in the bonding phase, the surface wear-resistant particle phase protrudes from the surface of the bonding phase to limit the rough surface of the self-regenerating wear-resistant particle structure, and after the surface wear-resistant particle phase falls off during the wear process, the lower wear-resistant particle phase is gradually exposed to achieve self-regeneration.
2. The self-regenerating wear-resistant particle structure according to claim 1, characterized in that: The wear-resistant particle phase is a layered structure uniformly dispersed and embedded in the binder phase, and each layer includes a plurality of spherical and nearly spherical hard particles.
3. The self-regenerating wear-resistant particle structure according to claim 1, characterized in that: The bonding phase accounts for 60%-80% of the total mass of the self-regenerating wear-resistant particle structure, and the wear-resistant particle phase accounts for 20%-40% of the total mass of the self-regenerating wear-resistant particle structure.
4. The self-regenerating wear-resistant particle structure according to claim 1, characterized in that: The thickness of the self-regenerating wear-resistant particle structure is 0.15 mm to 2 mm.
5. The method for preparing a self-regenerating wear-resistant particle structure according to any one of claims 1 to 4, characterized in that: The preparation method adopts thermal spraying, and the first powder is simultaneously heated to a completely melted or nearly completely melted state, and the second powder is heated to a semi-melted or slightly melted state. The particles of the first powder wrap the particles of the second powder to form a self-regenerating wear-resistant particle structure, wherein the dense bonding phase formed by the solidification of the first powder after melting provides bonding to the wear-resistant particle phase.
6. The preparation method according to claim 5, characterized in that: The thermal spraying method is atmospheric plasma spraying, conventional flame spraying or supersonic flame spraying.
7. The preparation method according to claim 6, characterized in that: Using the coaxial double powder feeding method, the first powder is fed into the ion flow transmitted along the central axis of the plasma gun through the first powder feeder, and the second powder is fed into the ion flow transmitted along the central axis of the plasma gun through the second powder feeder in front of the first powder feeder. During the transmission process, the first powder is simultaneously heated to a completely melted or nearly completely melted state, and the second powder is heated to a semi-melted or slightly melted state. In the plasma flame flow, the particles of the completely melted or nearly completely melted first powder wrap the particles of the semi-melted or slightly melted second powder, forming a self-regenerating wear-resistant particle structure.
8. The preparation method according to claim 7, characterized in that: The average particle size of the first powder is 15 μm-30 μm, the average particle size of the second powder is 35 μm-50 μm, and the distance between the second powder feeder and the first powder feeder is 41 mm-80 mm.
9. The preparation method according to claim 8, characterized in that: The feeding speed of the first powder is 10g / min-20g / min, and the feeding speed of the second powder is 30g / min-40g / min.
10. The preparation method according to claim 6, characterized in that: The particle size of the first powder is smaller than the particle size of the second powder.